Challenge

Project 2

PROJECT - 2

AIM = 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.

RULES IN ROUTING

Provide clips/clamps as per requirement.
Make sure that there is no any fouling case while designing the wire harness. Additional clips/clamps may be used to avoid fouling case.
Give additional slack if needed. 5-10% slack is sufficient.
Enough Clips Clamps shall be provided to ensure positive clearance with surroundings and safety of wiring harness.
Fir tree clips and other clips can be added to the geometrical bundle as they are electrically defined and are part of the wire harness routing and should be provided with the wire bundle package.
Avoid routing on sharp edges or else provide protection over the harness.
Follow the clearance distance and keep away the harness from heat generation components.
Protection should be provided as needed according to surrounding temperature.
Routing through small structural holes and openings shall be avoided. To minimize chaffing and handling of the wiring harness during installation.
Branch length should be greater than 50mm.the no of branch from a single branch point to 4.
Minimum distance between two branch points should be at least 50mm.
Minimum distance between clip and branch point should be at least 25mm.
The wiring harness should be easy to assemble and easy to access.

ASSUMPTIONS MADE

We have to route the wiring harness for,
- 2 x tail and indication lights
- Wiper Action, Number plate, and
- 2 x Automatic back door locking feature and connect them main electrical system of as car through an interconnection connector.
For tail and indication lights we used DEUSTCH 4 pole connector (DT06-4s).
For Wiper Action, Number plate, Automatic back door locking feature, used 2 pole connectors
A car body also have an interconnection connector which connects from a car body hatch to the, a car body wiring harness and is used a preferred location from where the routing for these lights starts.
We will use 12 pole electrical connector with a mounting clip as an interconnection connector.
As for the mounting parts clips/clamps which are used where ever necessary, HEllerman mounting clip are used.
This car BIW body requires a lot of mounting hole provision for the clips, it should be discussed with BIW design team and should be asked for these extra features and it will be finalized by the BIW design team.

PROCEDURE FOLLOWED

Defining all the connector cad data clips and clamps as required for routing the backdoor and add it to corresponding families in Catalogue.
We have to define geometrical parameters, bundle entry points and exit points from both left and right side of the clip electrically as a support in electrical part design workbench.

Mount the Fir tree clips on the Backdoor to provide support so we must first define it electrically with geometrical parameters, entry, and exit points on both the left and right sides of the clips.

Create Context assy with a new product file for the tail gate of car as the main assembly and it needs all the 3D Cad Data for the wiring Harness.
Add all the connectors, furr tree clips, sheet metal clamps in required position with the help of Manipulation Tool, Compass, Snap and Smart Move tools.
After positioning, start wiring harness from Interconnection Connector.

Though its completion, intiate Bundle Continuity in Edit>Search>Advanced>Workbench-Electrical Type-Bundle Segment>Attribute-Fully Connected.

Use Protective Cover to the bundle to ensure its safety with respective clearances.

Open a new product file for the Electrical harness Flattening and create a flatten view

The front view of the Backdoor wire Harness Flattening Product file must be inserted into the Drawing file. It should be noted that the 3D wireframe is always ON in settings.

CONCLUSION

Thus we had routed the given Backdoor Assembly with assumptions and prepared a flatten view in CATIA V5.

Ship work like this
in your own course.