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..

• 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

CLIP:

• The bend ratio for all the bundle segment is considered to be 1.4 AS follow to create the bungle segment.
• Routing of the wiring harness:
• 

Bundle Continuity Check :

• First, we have to select multi-branchable and go through the sequence as Edit>Search>Advanced>Workbench-Electrical>Type-Bundle Segment>Attribute-Fully Connected.
• After selecting 'True' condition will show all the connected bundle segments while selecting 'False' condition will show all the non-connected bundle segments.
• Here, we have selected 'True' condition and search for the results. All the bundle segments are highlighted and showing that all the bundle segments are connected electrically as shown in below image.

Preparing the flattening view of the wiring harness assembly :

create drawing:

• As shown in below image, we have to insert front view of the harness assembly into drawing file and define drawing properties.
• It should be noted that for the Dress-up feature 3D wireframe is always ON. If this setting is not selected then the bundle segments will not be visible on the drawing view.
• 

conclusion.

Routing of the wiring harness for the car tail gate assembly has done and prepared flatten-view drawing in Catia V5. Applied all the packaging rules while routing the wiring harness, implemented industry best practices in the harness design. Also, provided details like clearance, clipping selection, harness fixing requirements, harness continuity in order to design the harness.