Challenge

Project 2

AIM:

To route the Wiring harness on given car body back door and prepare flatten view drawing in CATIA V5.

Step 1- download the Back Door CAD data from the given source.

STEP 2 – Creating Holes on the given Back door data for reference purpose.

STEP 3 – Add required suitable Connectors.

Interconnection Connector:

C-1563689-1 used for Brake Light assembly connections and Wiper motor connection

STEP 4 – Placing fir tree clips to the required locations to ensure proper harness routing throughout the Assembly.

Ensure no fouling of harness to the back door sheet metal components.
Enough clamps shall be provided to ensure the positive clearance with surrounding and safety of wiring harness. Distance between two clamps/clips on a straight branch should be maximum of 200mm. However clamping requirements should be decided based on the harness bending and mounting arrangements.

STEP 6 - Wiring Harness Routing

Add branch points at minimum of 25mm distance from clips and clamps to create new sub branches connecting various connectors.
Minimum length of bundle should be 50mm.
Now, the car tail gate assembly is ready for the bundle routing as shown in below image
We have activated Geometrical bundle product file from the context assembly to create new multi-branchables.

STEP 7 – Applying Protective Cover

After bundle routing, we have to add protective covering to the harness bundle so that it will get protected from the damage.

Harness bundle should be protected with flexible rubber cover at the interconnection region where it is a critical place and subjected to opening and closing of door. There are more possibilities to damage the wiring harness if no proper protection covering is provided.
Corrugated conduits and protective hoses with various properties, from heat resistance through abrasion protection and impact strength to noise reduction, protect valuable cables against all unfavourable external influences.
Slit COT tubes are provided for protecting the harness from physical and other environmental damages that can occur in the long run.
Start or End Extrimities at the Connector bundle entry side should be given a gap of 30mm.

STEP 8 - ELECTRICAL CONTINUITY CHECK

We need to ensure that the entire bundle is fully connected.

Go to edit and then click on search command.
Go to advanced
Select workbench as electrical, type as bundle segment and attribute as Fully connected
The select result should be as TRUE or FALSE and the click search to see the connectivity analysis result.

Ship work like this
in your own course.