Project 2

Project 2: Designing a thorough Wiring Harness Assembly for a Car's Backdoor Using CATIA V5

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.

Back door :

Problem Description:

• The front and back views of a car's backdoor are displayed in the images above, and a wiring harness needs to be made for it.
• There will be a wire harness made for the number plate light and the taillights.
• There are two 2-pin connectors for the number plate light, two 4-pin connectors for the taillights, one interconnection connector, and 14 Omega clips for bundle routing.
• The wiring harness starts from the interconnection connector, passes through the Omega clips, and ends in the 2-pole and 4-pole connectors.
• All bundle segments should have a bend radius ratio of 1.4

Wiring Harness Routing Guidelines have to be Followed:-

• When designing the wiring harness, ease of manufacture, installation, removal, and maintenance must be taken into account.
• Avoid routing through tiny structural holes or apertures to reduce handling and chaffing during installation.
• When assembling or servicing a harness, avoid routing and clipping in regions that are difficult to access or in the blind zone.
• Provide additional slack when required according to the surroundings or the harness bending requirement. Slack values between 1% and 5% are used for this project.
• When designing the wiring harness in the CAD environment, it should be ensured that there are no instances of fouling. To prevent fouling, additional clips or clamps may be used.
• Protect the harness by avoiding routing it close to edges with sharp edges.
• There should be enough mounting tools like clamps and clips available.
• The branch length should be at least 50mm.
• A minimum of 25mm spacing should be kept between the clip and the branch point.
• There should be at least 50mm spacing between the two branch locations.
• The wire harness needs to be simple to assemble and access.
• To avoid paying extra costs for specialized mounting solutions, clips and clamps for the wiring harness should be easily obtainable from the market.

776438 (Interconnection Connector)

Sheet Metal Bracket

To provide parking for the interconnection connector, add an L-sheet metal bracket. Additionally, we must ensure that the bracket is positioned outside of the backdoor and geometrical bundle assemblies and inside the context assembly.

C-DT06-4 (4-Pole Connector)

C-DT06-2S (2-Pole Connector)

Clip

This mentined components are placed into Backdoor Assembly according to the data provided

Wiring Harness Routing

Routing is done using Electrical harness assembly Workbench

The bundle segment is routed from the interconnection connector, through the clips, up to the 2-pole and 4-pole connectors

The ratio of bend radius is maintained at 1.8

The thicknesses of all bundle segments are 5mm

Wiring Harness Flatenning

To flatten the wiring harness, create a new product file and save it with a representative name in the same folder as the backdoor context assembly. Then, select “Harness Flattening Parameters” and define harness flattening parameters on the “Electrical Harness Flattening” workbench. “Double line” for the bundle segment, and “Double' line” for the protective covering must be selected before producing the flattened view.

Drawing

To generate a drawing of the harness, open a new drawing file, select the command “Front View”, then go to the flattened harness window and select an appropriate face. Right-click the drawing sheet and select properties. In the view tab, select "3D wireframe" and "is always visible" in the dress-up settings to make the bundle segments visible.