Project 2

                                                                      PROCESS OF INSTALLING WIRING HARNESS

The placement of connectors, clips, and clamps in a vehicle's wiring harness is a crucial process during the manufacturing process,                         typically occurring at the automotive assembly plant. The process involves automated harness assembly, where wires are                                         cut and terminated to the required lengths, organized, and bundled together to form the specific harness for each part of the vehicle,                        including the back door harness. Connectors are attached to the ends of the wires to create plug-and-play connections                                              using automated crimping machines to ensure precise and secure connections. 

Clips and clamps are strategically placed along the wiring harness to secure it in position and prevent it from rattling or                                             interfering with other vehicle components. These clips and clamps are strategically located along the vehicle's body                                                   to keep the harness organized and protected. Once fully assembled, the wiring harness is carefully routed through                                                 the vehicle's body and integrated into the back door and other areas, paying close attention to proper routing                                                           to avoid interference with moving parts or sharp edges that could damage the wiring.

Testing is conducted after the wiring harness is installed to ensure all connections are secure and there are no faults in the                                        wiring, preventing electrical issues and potential safety hazards. The back door, with the wiring harness already integrated,                                        is installed during the final stages of assembly.

While there are general guidelines and industry standards for the placement of connectors, clips, and clamps, the specific                                          design and arrangement of the wiring harness can vary between different vehicle models and manufacturers.                                                      Each automaker may have its own unique assembly processes and techniques to ensure the reliability and safety of their vehicles.

 WIRING HARNESS LAYOUT

 below is an image for the layout of wirinh harness in the nissan Trail-X 

simmilarly we will do routing for our model and we should ensure that appropriate clips and clamps are used and also ensure that harness does not get damaged in the runnung condition 

STEP 1:

Create a new product in assembly workbench name it as backdoor context assembly and save it. now add the backdoor model to this assembly.

STEP  2:

Download the 3D data of required connectors and its mountings from the site www.te.com and import them into CATIA V5. Define the electrical properties by going to electrical part desing workbench and create the bundle conncection pont and cavity connection point

STEP 4:

Define other guiding devices electrically for P clamp and fir tree clip we need to use define the equipment option and then provide entry, exit and base plane, then define them electrically using define support part in the electrical part design workbench.

STEP 5: 

Insert all the connectors, clips, clamps and necessary parts for routing the wire and arrange them properly.  Place P clamps and fir tree clip wherever necessary based on the logics.

STEP 6:

Switch to the electrical harness assembly workbench and electrically define the geometrical bundle using the "Define Geometrical Bundle" option. Start the bundle routing using the "Multibranchable" command and define the bundle routing path from the interconnection connector to various components, including P-clamps and guiding channels. Route the harness completely and use adittional mountings if any additional requirement is felt.

STEP 7:

Add protective coverings, such as corrugated tubes, to avoid damage that can happen to the wiring harness

STEP 8:

Check the bundle continuity to ensure that all segments are fully connected.  Follow the design criteria for harness routing, considering factors like manufacturing ease, accessibility, removal, and maintenance of attached equipment, avoidance of sharp environments, clearance requirements, slack management, and harness protection.

Step 9: 

Flatten the wire harness by going to electrical flattening workbench, select harness flattening parameter, keep the product to be flattened opened in a new window. Click on the extract button and click on the context assembly where multibraching is done now we can see that the harness assembly gets exported, click on the flattening command and select the connector face on active plane and select all bracnhes. The model is flattened.

STEP 10:

To create a flatten view drawing of the wiring harness by creating a new drawing select the front view go back to flattened model and select the surface then flattened 2D view is obtained on the sheet left click to confirm the view. then save the drawing as image.