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. Available connector 3D data can be used, or you can download the connectors from www.te.com Prepare & Submit all necessary reports like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity, Assumptions if any along with CATIA 3D data.
AIM: Route the wire harness on back door and prepare flatten drawing using CATIA V5
OBJECTIVE:
* Route the wire harness for car back door.
* Prepare flatten view drawing in CATIA V5.
*Apply all packaging rules and industrial best price.
*Apply protection covering as required.
BACKDOOR
Back door is also called as tailgate. Back door in a car gives the access to luggage area and few cars have passenger compartment too. In most of the cars gas stay is used to operate the back door as it reduces the effort for the person opening. Few cars have electric motor to lift the back door when a switch is pressed. It is the rearmost part of the car and has mounts for tail lamp, hinges, wiper motor, gas stay etc. Back door is made up of 1 inner panel and 2 or 3 outer panels joined together by hemming and spot welding process.
Material used for the back door is chosen with various parameters like cost, strength required, weight, time taken to manufacture and so on. Steel is used in most of the cars as it is cheaper, these are stamped using molds and these parts will be uniform in thickness. Reinforcements are added to increase the strength locally.
Types of Back door
<!-- [if !supportLists]-->· <!--[endif]-->Top mounted
<!-- [if !supportLists]-->· <!--[endif]-->Side mounted
<!-- [if !supportLists]-->· <!--[endif]-->Bottom mounted
Based on working mechanism
<!-- [if !supportLists]-->· <!--[endif]-->Gas stay type
<!-- [if !supportLists]-->· <!--[endif]-->Powered lift type
Packaging rules and assumption made in the project
<!-- [if !supportLists]-->· <!--[endif]-->Avoid harness routing and clipping in blind zone
<!-- [if !supportLists]-->· <!--[endif]-->Provide additional slack to the according to surroundings
<!-- [if !supportLists]-->· <!--[endif]-->Provide enough clearance for the wire harness
<!-- [if !supportLists]-->· <!--[endif]-->Provide guiding channel if required
<!-- [if !supportLists]-->· <!--[endif]-->Enough clamps to be provided to ensure positive clearance with surrounding
<!-- [if !supportLists]-->· <!--[endif]-->Distance between two clamps in same branch to 200 mm
<!-- [if !supportLists]-->· <!--[endif]-->Use rubber grommet for protection and vibration
<!-- [if !supportLists]-->· <!--[endif]-->Branch length should be minimum 50 mm
<!-- [if !supportLists]-->· <!--[endif]-->Minimum distance between clip and branch point should be 23 mm
<!-- [if !supportLists]-->· <!--[endif]-->Maximum branches on a single point should be 4
TECHNICAL SPECIFICATIONS AND ASSUMPTIONS:
<!-- [if !supportLists]-->· <!--[endif]-->Wiring harness routing shall be ease in manufacturing, accessibility, maintenance and removal.
<!-- [if !supportLists]-->· <!--[endif]-->Avoid routing through small structural holes, bolts, bolted joints, screwed joints to avoid harness puncture
<!-- [if !supportLists]-->· <!--[endif]-->Provide additional slack to the harness according to the surrounding and harness bending requirements.
<!-- [if !supportLists]-->· <!--[endif]-->Provide additional slack to the harness branch which connects to the loads and covered with enclosures.
<!-- [if !supportLists]-->· <!--[endif]-->Avoid routing near sharp edges or over the sharp edges, in case of non avoidable situations additional protection should be provided.
<!-- [if !supportLists]-->· <!--[endif]-->Ensure harness is routed at least 100mm away from ABC pedals.
<!-- [if !supportLists]-->· <!--[endif]-->Enough clips and clamps shall be provided to ensure the positive clearance with surroundings and safety of wiring harness.
<!-- [if !supportLists]-->· <!--[endif]-->Keep the harness away from engine heat generation components, heating lines and EGR components.
<!-- [if !supportLists]-->· <!--[endif]-->Avoid direct support of harness on fuel lines routed in engine, in that case a separator clamp to be provided to satisfy clearance requirements.
<!-- [if !supportLists]-->· <!--[endif]-->Harness branch length should minimum 50mm.
<!-- [if !supportLists]-->· <!--[endif]-->Minimum distance between clip and nearest branching point should be 25mm.
<!-- [if !supportLists]-->· <!--[endif]-->Limit the number of branches from single branching point to 4.
<!-- [if !supportLists]-->· <!--[endif]-->Harness Protection should be provided according to the surrounding temperature.
<!-- [if !supportLists]-->· <!--[endif]-->Clips/Clamps that are used should be selected such that they are easily available in the market.
PROCEDURE:
DOWNLOAD BACKDOOR FILE
Creating Car body context assembly and Geometrical assembly
Car body hatch context assembly contains 3D data of car body hatch and all the non electrical data are stored in it and also the geometrical bundle assembly which consists of the electrical data needed for the project.
Defining connectors and mounting equipments electrically and position it.
- Define part as electrical connector.
- Define bundle connection point.
- Define connector connection point.
- Define cavity connection point.
CONNECTORS POSITIONED FOR:
<!-- [if !supportLists]-->· <!--[endif]-->Inter connection Connector
<!-- [if !supportLists]-->· <!--[endif]-->High Mount stop Light connector
<!-- [if !supportLists]-->· <!--[endif]-->Wiper motor connector
<!-- [if !supportLists]-->· <!--[endif]-->Number plate light connector
<!-- [if !supportLists]-->· <!--[endif]-->Tail lamp connector
<!-- [if !supportLists]-->· <!--[endif]-->Back sensor connector
<!-- [if !supportLists]-->· <!--[endif]-->Locking mechanism connector
<!-- [if !supportLists]-->· <!--[endif]-->Tail lamp connector
<!-- [if !supportLists]-->· <!--[endif]--> Defogger connector
INTER CONNECTION CONNECTOR
The Interconnection Connector is used to connect the wire harness of the backdoor with the vehicle body wire harness.
HIGH MOUNT STOP BRAKE LIGHT CONNECTOR
WIPER MOTOR CONNECTOR
NUMBER PLATE LIGHT CONNECTOR
TAIL LAMP CONNECTOR
BACK DOOR SENSOR CONNECTOR
LOCKING MECHANISM CONNECTOR
PROCEDURE
<!-- [if !supportLists]-->· <!--[endif]-->Placing fir tree clips to the required locations to ensure proper harness routing throughout the Assembly.
<!-- [if !supportLists]-->· <!--[endif]-->Ensure no fouling of harness to the back door sheet metal components.
<!-- [if !supportLists]-->· <!--[endif]-->Add branch points at minimum of 25mm distance from clips and clamps to create new sub branches connecting various connectors.
<!-- [if !supportLists]-->· <!--[endif]-->Minimum length of bundle should be 50mm.
<!-- [if !supportLists]-->· <!--[endif]-->Now, the car tail gate assembly is ready for the bundle routing as shown in below image
<!-- [if !supportLists]-->· <!--[endif]-->We have activated Geometrical bundle product file from the context assembly to create new multi-branchable.
<!-- [if !supportLists]-->· <!--[endif]-->First, we have started bundle routing from interconnection connector to the nearest Mounting clip available and continue to add multi-branchable bundles to achieve the required harness bundle. Main bundle harness diameter is considered as 15mm.
<!-- [if !supportLists]-->· <!--[endif]-->Enough clamps shall be provided to ensure the positive clearance with surrounding and safety of wiring harness. Distance between two clamps/clips on a straight branch should be maximum of 200mm. However clamping requirements should be decided based on the harness bending and mounting arrangements. Now add branch point for creating sub bundle connection for Wiper motor and number plate connectors.
<!-- [if !supportLists]-->· <!--[endif]-->Add sub bundle segments with bundle diameter 10 mm.
GEOMETRICAL BUNDLE ASSLY.
FLATTENING
DRAWING
PROTECTIVE COVERING
FLATTENNING WITH PROTECTIVE COVERING
FINAL DRAWING