Project 2

WIRING HARNESS FOR TAILGATE

Aim : The main objective is to route a wiring harness for a tailgate of car in Catia V5.

In this project, the wiring harness will be carried out following all the standard practices and design parametres. Later, will flatten the bundle and create a draft sheet too.

Given is the tailgate.

Points to be considered :

• Have to consider two bundles - one for tail lamps and another for registration plate lights. Reason is the lights of registration plate and brakes have different working principles
• To consider 2 inter-connectors, 2 for tail lamp housings and 2 for registration plate lights
• To consider necessary clips and clamps for better routing
• Minimum distance between branch points to be more than 50mm
• Branch length to be more than 50 mm
• Bend radius ratio value to be between 1.4-1.5
• To provide necessary slack to the bundle segments
• Avoiding scrapping with sharp edges
• Providing necessary protective coverings like Cot tubes

Steps to follow to create a harness bundle :

• Create a context assembly in Electrical Harness Assembly workbench which includes the tailgate body, geometrical bundle for taillamps and geometrical bundle for registration plate
• Define all the necessary connectors electrically and add them into the geometrical bundle. Define them with the bundle entry point and connector connection point
• Define required fir-tree clips electrically too for support and routing. Define them as supports
• Create branchables with suitable diameter and bend radius and provide adequate slack to them
• Cover the bundles with protective coverings like Cot tubes
• After connecting all the connectors, check for bundle connectivity. If fully connected, can proceed for flattening
• Create a flattening of entire harness in Electrical Harness Flattening workbench
• Switch to Drafting workbench and create a flattened drawing of the same

Refer to the images below

Geometrical Bundle Assembly

Bundle for tail lamp housing

Bundle for registration plate lights

Tree Structure

Flattened view

Drawing sheet