Project 2

STATEMENT OF ASSIGNMENT:

Route the Wiring harness on Given car body and Prepare flatten view drawing in CATIA V5. Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required.

OBJECTIVES:

• To define all the connectors electrically and save it in the Catalogue.
• To place all the connectors at the required position.
• To place Fir Tree clips at the required position by following the packaging rules.
• To create the Wire Harness Routing as per required and create branch points wherever required and also by following the packaging rules.
• To create the Wire Harness Flattening of the above routing.
• To display the flattened view in the drawing sheet.

GIVEN BACKDOOR ASSEMBLY

CONNECTORS USED

CATALOGUE CREATION 

SUPPORTING PARTS

• FURR TREE CLIPS

POSITION OF CONNECTORS

we need to place the connectors for various purposes in the backdoor like:

• Interconnection Connector (1)
• Brake Light Connectors (2)
• Indicator Light Connectors (2)
• Number plate light Connectors (1)
• Wiper Motor Connector (1)
• Door Lock connector (1)
• Rear camera connector (1)

CONTINUITY CHECK OF BUNDLE SEGMENT

SOME IMPORTANT PACKAGING RULES TO BE CONSIDERED DURING WIRE HARNESS ROUTING AND PLACING OF THE CLIPS AND CLAMPS:

• P - Clamps, Fir tree clips and other clips can be added to the Geometric bundle as they are electrically defined and are part of the Wire harness routing and should be provided with the Wire bundle package.
• The minimum bundle length should be 50mm.
• Enough slack should be provided so that the wiring harness does not get damaged during the Engine rocking or starting condition.
• The wire harness routing should be done in such a way that it is easy in manufacturing and serviceability.
• The wire routing should be done keeping in mind the cost effectiveness of the bundle package.
• To avoid the harness routing and clipping in blind zones of the operator during the assembly and the service.
• Additional slack should be given according to the surrounding and harness bending requirements.
• To avoid giving excess slack and avoid giving slacks wherever not necessary.
• To provide proper slack at end connectors so that there will be no tension on the wire bundle.
• To avoid sharp edges on the sheet metal parts and if it is not possible then provide protection parts to prevent damage of the wire bundle.
• The minimum distance between two straight connection points should be 200mm.
• The minimum distance between clip and the nearest branching point should be 25mm.
• The minimum distance between two breakout points should be 50mm.
• To limit the number of branches from a single branch point to 4.

FLATTENING OF BACKDOOR WIRING HARNESS

        Because of my software issue, CATIA can't run the Electrical Harness Flattening. It showed a pop-up "Electrical software error inside the flatten command".