Project 2

   To route the wiring harness on the given tailgate assembly and prepare the flattened view drawing in CATIA V5

Objective:

Route the Wiring harness on the Given car body and Prepare a flattened view drawing in CATIA V5. Application of all Packaging rules and industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required.

PROCEDURES AND STEP FOLLOWED FOR WIRING HARNESS ROUTING

• Created new product file and named it as “BACK DOOR WIRING HARNESS CONTEXT”.
• In that product I have opened the CAD file given for the Tail gate.
• Created another product file inside the wiring harness context assembly file.
• And named “GEOMETRICAL HARNESS BUNDLE BACKDOOR”
• I have prepared all the required connector, Clips, Clamps and protective CAD Data.
• Each components defined electrically by giving respective features.
• Created catalogue documents for particular groups.
• After creating the catalogues, added required connectors and clips from the catalogue browser.
• Using manipulation tool placed all the connectors and clips as required.
• Now for starting the routing first electrically defined the geometrical bundle assembly file using the command Geometrical Bundle.
• That leads to create new multi-blanchable part file inside the GEOMETRICAL HARNESS BUNDLE BACKDOOR.
• Then click on the multi-branchable command led to wiring harness installation work bench from there Using branch definition command started the routing.
• Given all the required parameters like wire radius, bending radius, slack and route definition.
• Created Branch points for adding branches on required positions.
• After well completion of all the connection routing, protective coverings for the wires were added.

Back Door Assembly Part:

   

Construction of the Harness Assembly Bundle:

Step 1: Creating Context Assembly:

A Context Assembly for Backdoor Wire Harness has been created, which will work as the main assembly as shown in the figure above.

A Context Assembly will contain Backdoor Assembly data and Backdoor Wire Harness Geometrical Bundle Assembly.

Step 2:

      Positioning the Connectors & Clip/Clamps to the Back Door Assembly:

Here, according to the requirement, we are using

‘C-776438’ Which is a 14 Pole connector is used as an inline Connector

'C-DT06-4S' which is a 3-pole connector for Taillight

'C-DT06-2S' which is a 4-pole connector for Number Plate Light

This CAD data was obtained from te.com. To electrically define a connector, we must first define the geometrical parameters such as the bundle connection point and connector connection point in the Electrical Part Design workbench for the downloaded connector.

For Support, we use Furr Tree Clips

We need to mount the Furr Tree clips on the Backdoor to provide support as well as act as a guiding channel, so we must first define it electrically with geometrical parameters, entry, and exit points on both the left and right sides of the clips, as shown in the figure below.

Step 3:

      Bundle routing from Interconnection:

Here, we are routing the bundle segment from the interconnection connector to Furr Tree. The diameter for this routing path is 10mm and the bend radius ratio is assumed to be 1.4.

we can see that the bundle segment inside the guiding channel is created by using the pre-made sketch as the routing definition.

In above figure, we are routed bundle segment from the newly created branch points to the 8 fuel-injector connectors. 

Similarly, we have done routing for the left side guiding channel also as shown in the figure.

Step 4: 

        Adding protective coverings:

 Here in below figure, we have done with whole wiring harness routing for the Engine. Now, we have to add protective coverings to all bundle segments.

step 5: Checking Bundle Continuity:

in this step, first we have to make sure that multi-branchable is selected then we have to go in Edit>Search>Advanced>Workbench-Electrical>Type-Bundle Segment>Attribute-Fully Connected 

By selecting 'True' option will show all the connected bundle segments while selecting 'False' option will show all the non-connected bundle segments. 

Here, we have selected for the 'True' option and searched for results. All the bundle segments are highlighted found showing that all the bundle segments are electrically connected as shown in below figure.

Check For not Fully Connected Bundle:

Step 6:

       Flatten the Bundle Routing:

In this step, to create flatten view we have to work on the Electrical Harness Flattening workbench of Catia V5. We should also make sure that the flattening file is saved in the same folder where other files of harness assembly are saved. 

We have extracted the bundle assembly into the Engine Harness Flattening Product file and then flattened the file along face of the interconnection connector as shown in above figure.

At this stage, for clarity, we have been hidden the flattening diagram of the plastic guiding channels from the drawing view.

Step 7:

       Creating the Drawing File For this Flattened Bundle segment:

Creating new drawing file and defined all the necessary drawing parameters. We have to insert the front view of the Engine Harness Flattening Product file into the Drawing file.

We have to define drawing properties as shown in above figure. It should be noted that in 'Dress up' settings 3D wireframe is always ON. If this setting is not selected then th bundle segments won't be visible on drawing view.

Conclusion:

• Thus, Finally, the Bundle Assembly is Routed With a Protective Covering And Creating Drawing and now the Drawing is Ready For pre-release for Production.