Project 2

Wiring Harness Routing on Car Backdoor

AIM:

Route the Wiring harness on Given car body and Prepare flatten 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 Car backdoor.
• Develop 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 runs throughout the entire vehicle and transmits 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 the 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 harness 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 choices for hybrid cars since they offer exceptional performance in challenging settings as well. This indicates that these harnesses can handle electrical loads, 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.
• Electrical 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 embed into speed sensors, lock breaking systems, cruise control systems, and fuel injection systems.
• Chassis wiring comprise of the front, rear and main harnesses.

3D MODEL OF VEHICLE BACKDOOR

Electrically Defined connectors

Beginning of routing from connector to fir tree clip

Routing throuth fir tree clip :

Electrical branch definition:

Sub-branch created to connector:

Developed corrugated tubes for routing:

Bundle routing completion:

Developed electrical bundle routing for backdoor:

Assembly harness geometrical bundle segment:

Flattening product of harness bundle:

Cad drawing of flattened harness bundle:

Steps followed

• Defined connector, Bundle connection point and connector-connection point for 1563681-1 Connector.
• Defined connector, Bundle connection point and connector-connection point for 173090-2 Connector.
• Defined connector, Bundle connection point and connector-connection point for 1743572-2 Connector.
• Defined Bundle entry and exit point for Furr tree clip.
• Created a electrical context assembly
• Imported car backdoor in to the context assembly.
• Created new bundle product file in context assembly.
• Imported all the connectors, clips and channels required for the bundle assembly.
• Connector assembly is performed in assembly design using smart move option.
• Furr tree clips are provides in betwwen the connectors for the better routing.
• Defined the bundle assembly in to the Electrical harness assembly.
• Defined branch definition.
• Conneted the electrically defined parts using route definition.
• Created brach points in betwwen the connectors using add branch point option.
• Bend radius ratio is set as 1.4.
• Should ensure that the Bend radius should be less than computed bend radius.
• Automatic offset connection is enabled.
• Developed flattening of routed product in electrical flattening workbench.
• Created the drawing for the flattend product.

CONCLUSIONS

• Electrical connections for all the components are done successfully.
• Electrical Harness Routing for vehicle backdoor has developed successfully.
• Flattening of electrical routing product has developed successfully.
• CAD Drawing Has created from developed flattend product.