Project 2

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.

Available connector 3D data can be used, or you can download the connectors from www.te.com

Prepare & Submit all necessary reports like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity, Assumptions if any along with CATIA 3D data.

The trunk or boot of a car is the vehicle's main storage or cargo compartment it also have a hatch at the rear of the vehicle. It is also called a tailgate. These doors can be operated manually or electric powered. here we design the trunk or back door wire harness using the Catia.The Backdoor is an assembly of many parts such as inner panel, outer panel upper, outer panel lower and Reinforcement. Inner panel is attached to the outer panel using mastic sealant.

Types of doors based on working position

1. Top Mounted Door
2. Side mounted Door
3. Bottom Door

Rules to be followed:

1. Wiring harness should be routed in such way that it is easy to assemble and access.
2. Easy manufacturing, installation, removal and maintenance have to be considered while designing the wire harness.
3. wiring Harness should be kept away from sharp environment like edges, corners etc.
4. Avoid harness routing and clipping in the blind zones or hard to reach areas during harness assembly or service.
5. Provide additional slack if needed according to the surrounding and harness bending requirement. If harness is passing through the closures/doors or tail gates then envelope dimensions during opening and closing of doors shall be considered to provide the slack. Check the harness slack requirements with open and close conditions to avoid excess slack.
6. Routing through small structural holes and openings shall be avoided. To minimize chaffing and handling of the wiring harness during installation.
7. It should be make sure that there is no case of fouling while designing the wiring harness in the CAD environment. Additional mounting equipments like clips/clamps may be used to avoid fouling.
8. Use of rubber grommet is recommended if harness is passing through sheet metal panels. Example- firewall, passing to door, tail gate etc.
9. The branch length should be greater than 50mm.
10. The minimum distance between the clip and branch point should be at least 25mm.
11. The minimum distance between the two branch points should be at least 50mm.
12. Clips/clamps used for the wiring harness should be easily available in the market to avoid extra cost for custom mounting solutions.

Defining connectors electrically

Taking Required components for the wire harness routing. Here we are using the components for backdoor upper and lower lights, wiper motor, sensors, and defogging equipment. The connectors used are first electrically defined and then added to the CATIA model.

The type of connectors used are given below-

1. Interconnection connector.

Check for the bundle continuity and bundle warnings in the wiring harness assembly and resolve them

• Under the edit command select the search icon (binocular symbol) a pop-up window will appear to select the advanced option and arrange the options available by selecting, workbench as electrical, type as bundle segment and attribute as fully connected.
• A pop-up window will appear, while selecting it as false and selecting the search button it will show all the discontinued bundles in the assembly. If we select it as true, it will show a fully interconnected bundle throughout the assembly.
• Bundle warnings are mainly due to the inappropriate bend radius given to the bundle this can be solved by adjusting the position of connectors, adjusting the bundle break point for sub-branches, reversing the tangency of the bundle, adding extra slag, etc.
• It is recommended to maintain the tentative bend radius always less than that of the computed bend radius of bundles.
• Back Door VIEWS :

wiring :

• The routing starts with interconnection connector placed on the Backdoor.
• It is continually routed to the following supports.
• The major routing supports used here are the p-clamps and furr tree clip.
• The back light connectors are routed.
• The connectors for the wiper motor equipment.
• The connectors for the number plate lights and the sensors.
• Now by using multi-branch bundle route all the connector with the clip and clamp.