Project 2

AIM:-

• To generate the the wire harness for the given BIW component,tail gate .The routing has to be generated for the tail lamp and the number plate lights with allocated space available which can be used as advantage.

DESIGN CRITERIA:-

• Connectors selected 4 pole connectors for the interconnection.
• Bundle diameter is set to 5mm
• Bend radius ratio is kept 1.5 for the tail lamp geometrical bundle and 1.4 for the number plate bundle
• 10mm protective cot tubes are used for both geometrical bundles
• The support devices used for the routing are firtree clips total 19,10 for the tail lamp bundle and 9 for number plates
• There was no requirement for gromets or other water resiliant support devices cause the routing is packed inside and over the tail gate the plastic component is attested,thus simple cot tubes are fine.

Defining the electrical components:-

• To define a component as electrical open the electrical part design and import the part.
• select the desired component and define it accordingly.The below options reperesent the defination for unique component
• Choose the appropriate part and define the no.of terminals for connectors what type of connectors its is etc..,
• Example while defing a 2-pole connector a dailog box pop ups as shown
• 
• here define the type of connector and enter the no.of terminals associated with it
• when it is defined the electrical defination symbol is add to feature tree
• After defining the component define the geometrical parameters for the component
• After defining the electrical part which is connector here next to define geometrical parameters using the above options this dialog box opens
• 
• select the connector then select the point following with coincidence face and orientation face from the axis system defined.
• Next select the bundle connection point option the following pop up opens
• Similarly while defining the support parts we just define the part as electrical using the options.
• 

Electrically defined components:-

POSITIONING OF THE CONNECTORS IN THEIR EWQUIRED POSITIONS:-

• After the components are electrically defined position them as shown as below
• Tail lamp firtree clips positions as shown below,the black highlight represents the firtree clip position.

• number plate routing firtree clip positions

WIRE HARNESSING:-

• Now that we have all the electrical parts positioned and the geometrical bundle defined,we are good to go for the routing.
• To create the routing we should work on ELECTRICAL HARNESS ASSEMBLY itself and select the multi-branchable option as shown in below diagram.
• When we activate this we will be automatically redirected to the ELECTRICAL HARNESS INSTALLATION workbench.
• 
• This actives the the multibranchable features then the below pop up appears.
• 
• In the branch defination we have to defined the bundle radius and the set the bend radius ratio as 1.5 and slack put here zero
• When the slck was given to a certain value,it was fouling with the tail gate ,thus slack is not given.
• Next is to start the routing by clicking the route defination option,in this we select the firtree clips and external points and define a route for wire.
• 
• We have 3 differnt options like add before , add after and replace which we use select the next part or before part or replace the part or point.
• After creating the routing click OK and we are reverted back to branch defination and again select OK,your bundle is generated.
• For adding a sub branch we should select ADD BRANCH POINT option which cuts the current branch,through which we can route another branchable.We can also delete the branch point and branches using the DELETE BRANCH POINT and DELETE SPECIAL options.
• 
• Above is the harness for the tail lamp and below is the harness with the cot tubes
• 
• Follow the same method for the harness of the Number plates routing but define the branch defination as shown
• 
• The diameter of the bundle is same but the bend radius is set to 1.4 and method of routing is same as that of the Tail lamp
• 
• 
• 

FLATTENING:-

• Now that we have created the harness routing for the engine we have to create the flatenning of the model which is again converted to a 2d drawing.
• To ensure a smooth flatenning we should make sure all the branches are connected.
• We can check the bundle connectivity using the SEARCH option.
• Open the search option by clicking on the option or Ctrl + F is the shortcut for the search.
• Select the ADVANCED and in advanced select electrical in workenech,Bundle segment in Type, attribute can be TRUE OR FLASE.I have selected false.
• So, it will show if any bundles are not connected and list them out,here our bundles are fully connected thus,we can go for flatenning without expecting unnecessary errors.
• 
• After checking the bundle segment connectivity switch to ELECTRICAL HARNESS FLATENNING.Three boxes will be there on top they are define Flatenning ,extract and flaten.
• 
• select he flattening option and define the flattening parameters as shown
• 
• Next select the extract option nex to the flattening and select our model ,The product and the multibranchable are saved as EHf parts as new bundles
• next step is to flatten the model by selecting the flatten option next to the extract and this pop up appears.

• 

• The fattening is seperately done for the both geometrical bundles of tail gate

• 

• You acn select any face as active to represent as the reference.And use the rotation tool and other tools to make in flatten as shown below down.
• When a flatten model is created it is automatically saved as EHf product and so in the flatten model every electrical product to appear we should save all the parts in single,for this fimction we can use the save management option and click propagate directory which will put all parts in the single folder.
• The is automaticaly converted to the Ehf product as shown changes in the feature tree itself.
• 

CREATING THE 2D DRAWING FROM THE HARNESS:-

• So that the flatten model is done next step is to create the drawing
• For effective drawing representation we should modify/ensure some specifications in the flattening parameters as shown below.
• The changes made here will reflect in the 2d drawing sheet.
• 
• After ensuring the desired options create new drawing document an select the type and size of the drawing sheet.
• 
• Now rearrange the model to linear position so that it would fit into the sheet
• At first in the drawing the bundles wont appear,to make them appear double click and open properties in that select the wire frame and select ok,your bundle will appear.
• You can also enable the hidden line and centre lines for accurate repreaentation.
• After all the necessary dimensions are given and the drawing is validated,its forwarded to the manufacturing.
• Thus the wire harness routing for the given TAIL GATE part is completed.
• 

PLEASE FIND THE NECESSARY CATFILES IN THE BELOW UPLOADS