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.

STEP 1 - Creating context assembly

Open the Backdoor assembly in the catia making an assembly product file.

Give the Electrical properties to the connectors, and clip.

Connector 1:

 

Create a point on the mating surface and a point at the back as the bundle entry point. Create an axis on the point.

Connector 2:

Create a point on the mating surface and a point at the back as the bundle entry point. Create an axis on the point.

Make slot holes:

Do the same on the lower part.

 Start to align the clips:

Insert the clips and align them.

Use the 'Manipulation' and 'Smart Move' options to align the chip.

Making sure the clips are placed between 50 mm - 200 mm as per the design rules.

Insert the connectors and align them:

1 interconnection connector.

2 tail light connectors.

1 window wiper connector.

1 number plate light connector.

1 power lock/latch connector.

Start routing the bundle segments:

Create branch. 

The bend ratio is 1.4.

Slack of 1 - 5% is provided at the necessary location.

Apply protective covering to the bundle segments:

Keep the extremities 30 mm away from the connectors.

Flattening the Harness Assembly:

Create a new product and go into the "Electrical Harness Flattening" Workbench.

Click on the "Harness Flattening Parameters" option to adjust the parameters.

Rotate the bundle segments and align the clips accordingly. Use the Manipulation, Smart Move, and Roll options to align.