Project 2

Wiring Harness Routing of Back Door Panel of a Car

In this challenge, we will perform the Wiring Harness Routing of a Back Door Panel and at the end will prepare a flattened view drawing for the same. All packaging rules & the best industry practices will be followed during this process.

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The steps that need to be followed for executing this task are as follows:

• Identifying the electrical components in the model
• Defining the mechanical components electrically or Importing the data from the catalogue
• Setting up the assembly by placing the required connectors, clips, clamps, etc
• Proper routing of the bundle without any interference
• Preparation of flattening file & 2D drawing creation

The electrical components in this model are Tail Lights & Number Plate Lights. These lights require power or current to operate hence the wires or bundles that we are going to route today will help us understand the length & path of the wire & also the connectors, clips and other parts that are needed for this project.

For the lights, we are first going to define the mechanical components i.e, connectors, electrically.

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After which the support clips needed to be defined. These clips will help the bundle to be routed properly without any interference.

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The bundle for this component needs to be connected to the vehicle harness system hence an interconnection connector will also be used in this project.

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An L-type Clip or Bracket is used to place the interconnection connector.

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Once all the data is ready, we will create a context assembly under which 2 sub-assemblies are used, 1 sub-assembly will be the back door panel & another sub-assembly will hold the electrically defined components along with the bundle.

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The Harness Engineer needs to decide the path for routing the bundle by considering all the environmental factors such that there will be no interference or difficulty faced during the execution in real-time conditions.

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Once the routing is completed, we will check the bundle continuity & also provide a protective covering to avoid damage to the bundle.

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Bundle continuity is very crucial in order to provide a proper flattening diagram of the harness. BOM, Bundle length, Bends & other necessary information can be shared with the help of 2D drawing. This drawing will be released by the harness engineer for procurement of parts & manufacturing.