Project 2

AIM:

    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.

INTRODUCTION:

    The trunk or boot of a car is the vehicle's main storage or cargo compartment it also have a hatch at the rear of the vehicle. It is also called a tailgate. These doors can be operated manually or electric powered. here we design the trunk or back door wire harness using the Catia.The Backdoor is an assembly of many parts such as inner panel, outer panel upper, outer panel lower and Reinforcement. Inner panel is attached to the outer panel using mastic sealant

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.

PROCEDURE:

• STEP 1: DEFINE ALL THE COMPONENTS ELECTRICALLY

         First create catalog for connectors ,clips,clamps and corugated tube .When components electrically defined save to the corresponting catalogs.

12-pin connector - C-776438-4

C-173090-2

C-282080-1

C-1563689-1

p clamp

Fir tree clip

• STEP 2: CREATE CONTEXED ASSEMBLY

        For create an contex assembly create an product file and add the back door.then add new component and name it as assy_back door_geometrical bundle.

       add all electrically defined components in geometrical bundle product file.

• STEP 3: ARRANGE ALL THE COMPONENTS IN DESIRED LOCATION.

    Arrangement of clips

positioning connector for de fogger

positioning connector for bottom light

positioning connector for viper motor .here 4 pole connector is used

position of inter connector

positioning of connector for brake light and indicator.

• STEP 4: STRAT ROUTING

         Once all the connectors placed start bundle routing

continuity check

• STEP 5: APPLY PROTECTION COVERING

• STEP 6 : WIRING HARNESS FATENING

       Now we need to convert the geometrical bundle into a flattened wiring harness in the Electrical Harness Flattening Workbench

       To create the Flattened Harness , We need to create a new Product file and switch into electrical Harness flattening Parameters and then Extract the geometric bundle from the Wiring Harness Context product file

Then Select all the Branches and Flatten the entire Geometric Bundle

• STEP 7: CREATE THE DRAWING FOR THE FLATTENED PRODUCT FILE

        Insert the flattened harness product into the drawing sheet using view option and selecting the front view command

CONCLUTION:

      Routing of the wiring harness for the Backdoor assembly has been successfully done and prepared flatten view drawing in CATIA V5 as per the design requirements

"IAM NOT ABLE TO ATTACH THE PART FILR BECAUSE IT IS MORE THAN 20 MB. SO I ADD IN THR DRIVE AND THE LINK GIVEN BELOW"

https://drive.google.com/file/d/1Rtu06bN4VitPEjZGSU--MPf0HtsLOW9G/view?usp=sharing

https://drive.google.com/file/d/1Rtu06bN4VitPEjZGSU--MPf0HtsLOW9G/view?usp=sharing

https://drive.google.com/file/d/1Rtu06bN4VitPEjZGSU--MPf0HtsLOW9G/view?usp=sharing