Project 2

Aim: To route the wiring harness on the given backdoor assembly and prepare the flatten view drawing in CATIA V5.

Objective: The objective of this project is to route the wiring harness and prepare flatten view drawing for the Backdoor of the car. All types of packaging rules have to be considered while routing the harness and industry-based practices shall be demonstrated in harness design. All necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design the wiring harness.

Rules to be followed:

1. Wiring harness should be routed in such way that it is easy to assemble and access.
2. Easy manufacturing, installation, removal and maintenance have to be considered while designing the wire harness.
3. wiring Harness should be kept away from sharp environment like edges, corners etc.
4. Avoid harness routing and clipping in the blind zones or hard to reach areas during harness assembly or service.
5. Provide additional slack if needed according to the surrounding and harness bending requirement. If harness is passing through the closures/doors or tail gates then envelope dimensions during opening and closing of doors shall be considered to provide the slack. Check the harness slack requirements with open and close conditions to avoid excess slack.
6. Routing through small structural holes and openings shall be avoided. To minimize chaffing and handling of the wiring harness during installation.
7. It should be make sure that there is no case of fouling while designing the wiring harness in the CAD environment. Additional mounting equipments like clips/clamps may be used to avoid fouling.
8. Use of rubber grommet is recommended if harness is passing through sheet metal panels. Example- firewall, passing to door, tail gate etc.
9. The branch length should be greater than 50mm.
10. The minimum distance between the clip and branch point should be at least 25mm.
11. The minimum distance between the two branch points should be at least 50mm.
12. Clips/clamps used for the wiring harness should be easily available in the market to avoid extra cost for custom mounting solutions.

STEP 1 - Creating context assembly

Open the Backdoor assembly in the CATIA software making an assembly product file.

 

STEP 2 - Defining connectors electrically

• Obtaining the necessary components for wire harness routing.
• The components for the backdoor upper and lower lights, wiper motor, sensors, and defogging equipment are used here.
• The connections are electrically specified first, then incorporated to the CATIA model.

STEP 3 - Adding connectors and needed equipments

STEP 4 - Bundle routing

•           The routing process begins with an interconnection connector installed on the Backdoor.

•           It is constantly directed to the following services.

•           The p-clamps and furr tree clips are the main routing supports employed here.

•           Backlight connections have been routed.

•           The wiper motor equipment connects.

•           The sensors and the connections for the number plate lights.

•           Route all of the connectors with the clip and clamp using the multi-branch bundle.

STEP 5 - Bundle continuity check

•           We are now checking the bundle continuity check for the next procedure.

•           The TRUE and FALSE criteria' continuity was tested.

STEP 6 - Adding protective covering to the harness bundle

We safeguard the entire bundle by employing the protective covering tool. We developed a catalogue and included protective covers with 15 mm and 8 mm diameters and PVC tape. Here, we create a space between the end and the beginning extremities.

STEP 7 - Create flatten view

We're now going to create a new product file for the Electrical harness flattening. Here, we save the previously created geometrical bundle segment and extract the geometrical bundle to flatten harness using flattening settings.

After the branches have been flattened, we modify them using the rotate, bend, and straighten tools in the Electrical harness flattening.

STEP 8 - Creating a flatten view drawing

The picture above is a 2D flattened view of the backdoor wire assembly.

Conclusion: The wire harness for the Backdoor assembly was successfully routed, and a flatten view drawing was created in CATIA V5 in accordance with the design specifications.