Project 2

                                          PROJECT2:- WIRING HARNESS ROUTING ON CAR BACKDOOR

PROBLEM DEFINITION:

Route the Wiring harness on the given car body and prepare a flattened 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.

OBJECTIVES:

• Define the connectors, clips, and clamps electrically for the harness bundle routing for car backdoor.
• Develop a Bundle Routing in the car backdoor.
• Develop a flattening model for created bundle assembly.
• Create a drawing for routed engine assembly.

THEORY:

A wiring harness is a logical arrangement of wires, terminals, and connectors that run throughout the entire vehicle and transmit data and electrical power, effectively "connecting" a number of different components. Similar to how the circulatory and central nervous systems of the human body transmit energy and information, this network does the same. Wire harnesses are collections of electrical cables used in electrical applications to carry signals. They are a collection of slack wires that have been bundled into a single covering to create a more streamlined system. Many other industries employ these wire harnesses, with the automotive industry being one of the biggest users.

For optimum performance, automotive wire harnesses employ a wide range of wire harnesses. These harnesses integrate the electrical and electronic device wiring from several devices into a single system. As a result, they support the transfer of signals and the activation of various electrical and electronic equipment. They are made to work successfully in harsh environments and are also used to set up electrical circuits in autos.

BENEFITS OF AUTOMOTIVE WIRING HARNESS:

Reduced installation time:

Consider adding numerous wires to your system. Then, think of installing a single device that connects several wires. It goes without saying that installing a single unit is far quicker than installing many units. Additionally, this lessens the possibility of faulty wiring.

Reduced risk of shorting:

The use of wire harnesses reduces the chance of electrical circuit shorts by combining many wires into rigid bundles, making them safer than loose wires.

Great Performance in harsh conditions:

The materials used to make automotive wiring harnesses are strong, making the harnesses strong as well. These bundles are made to function remarkably well in challenging environments and to carry large power loads.

Improved Fuel efficiency:

Every vehicle's ability to increase fuel efficiency is greatly helped by wiring harnesses.

Performance in hybrid cars:

Automotive wire harnesses are the ideal choice for hybrid cars since they offer exceptional performance in challenging settings as well. This indicated that these harnesses can handle electrical loads, and withstand high heat and electromagnetic noise while still transmitting large currents under challenging circumstances.

 APPLICATIONS OF AUTOMOTIVE WIRING HARNESS:

• Two-wheelers, three-wheelers, cars, utility vehicles, and commercial vehicles.
• Electrically and geometrical requirements of automobiles, and are embedded in the body, engine, and chassis of vehicles.
• Body wiring harnesses are embedded into dashboards, door locks, power windows, and interior electrical components.
• Engine wiring harnesses are embedded into speed sensors, lock-breaking systems, cruise control systems, and fuel injection systems.
• Chassis wiring comprises the front, rear, and main harnesses.

3D MODEL OF VEHICLE BACKDOOR:

                     

                     

Electrically Defined 1563681-1 Connector:

Electrically Defined 173090-2 Connector:

Electrically Defined 282080-3 Connector:

Electrically Defined Fir Tree Clip:

Beginning of routing from connector to Fir Tree Clip:

Electrical branch definition:

Routing through fir tree clip:

Sub-branch created to connector:

Applied corrugated tubes for routing:

Developed electrical bundle routing for backdoor:

Assembly harness geometrical bundle segment:

Flattening Product of harness bundle

Drawing of Flattened Harness Bundle:

• Conclusions:

Electrical connections for all the components are done successfully.

Electrical Harness Routing for vehicle backdoor has developed successfully.

Flattening of electrical routing products has developed successfully.

CAD Drawing has created from developed flattened product.