Project 2

Aim: To route the wiring harness on the given tailgate assembly and prepare the flatten view drawing in CATIA V5. 

Given:

Car Tailgate Assembly                            

                                                                 

                                                                 

   

DESIGN CRITERIA AND PACKAGING ASSUMPTIONS:

• Wiring harness routing shall provide ease in manufacturing, accessibility, easy removal, and easy maintenance of attached equipment and wiring harness.
• Routing through small structural holes and openings shall be avoided, minimize chaffing and handling of the wiring harness during installation.
• Avoid the harness routing and clipping in the Blind zone of the Operator during harness assembly or in service.
• Routing shall offer protection against possible damage through common misuses such as being handhold and temporary support for test equipment.
• Provide additional slack to the harness according to the surroundings and harness bending requirements.
• Ensure the routing meets the clearance requirements with different surrounding parts.
• Avoid routing over the bolts, near to the bolted joints. It may damage the harness or puncture the harness. Keep harness away from panel mounting screws.
• Avoid harness routing near sharp edges, if not possible provide protection to the harness.
• The maximum distance between two clips on a straight branch is 200mm.
• Provide Clips and clamps if the harness is going to bend at multiple locations.
• The use of too many sheet-metal brackets should be avoided.
• The branch length should be more than 50 mm.
• Min distance between clip and branching point to be 25 mm.
• Min distance between two branch breakouts should be 50 mm.

                                                    

Routing the Wiring Harness:

1. First, we have to consider the components we need for the routing. Here we are only considering the taillights and the number plate lights. 
   
   
2. Here we are considering 2 different types of connectors as follows
   
   Interconnection Connector:
   
   
   
   
   
   Light Connector
   
                                                             
   
   
3. Clips used for routing the harness
   
   Fir tree clip 10mm                                                                                                   Fir Tree clip 5 mm 
   
                 
   
   
4. Defining all the connectors as electrical components and the clips as the supporting equipment.
   
   
   
   
   
   
   
   
   
                                                                  
   
   
5. Routing of the wiring harness
   
                                                       
   Bundle Continuity Check 
   
   
        
   
6. Application of protection coverings
   
                                                             
   
   
7. Preparing the flattening view of the wiring harness assembly 
   
   
            
   
   
   
                 
    Drafting of the Wiring Harness :
   
   
   
   CONCLUSION:
   
   
   The wiring harness has been designed for the given tailgate assembly and the flattened view is drafted.