Project 2

 Aim:-

• To route the wire harness on the given tailgate assembly and prepare the flatten view drawing on CATIA V5.

 Objective:-

• The objective of the project is to route the wiring harness and prepare a flatten-view drawing for the given car body hatch. All types of packaging rules and constraints have to be considered while routing the harness. Industry-based practice should be implemented in the harness design. All the necessary details like clearance/clamping selection, harness fixing requirements, harness continuity should be provided to design the wiring harness. 

Design criteria and packaging assumption:-

• Wire harness routing shall provide ease in manufacturing, accessibility, easy removal, and easy maintenance of attached equipment and wiring harness.
• Routing through small structural holes and openings shall be avoided, minimizing chafing and handling of the wire harness during installation.
• Avoid harness routing and clipping in the blind zone of the operator during harness assembly or in service.
• Routing shall offer protection against possible damage through common misuses such as being handhold and temporary support for test equipment.
• Provide additional slack to the harness according to the surrounding and harness bending requirement.
• Assuring the routing meets the clearance requirements with different surrounding parts.
• Avoid routing over the bolt, near the welded joints. It may damage the harness. Keep harness away from panel mounting screws.
• Avoid the harness routing near the sharp edge, if not possible then use a protective cover on it.
• Provide clip and clamp at the bending point.
• Min distance between clip and branching point to be 25mm.
• Min distance between two branch breakouts should be 50mm.

Routing the wire harness:-

1. First we have to consider the component we need for the routing. Here we are only considering the taillights and the number plate lights.
2. Here we use 2 different types of connectors.

Defining all the connectors as electrical components and clips as a support member:

Interconnection connector (C-776438-4):

Taillight connector (C-1563689-1):

Fir tree clip:

Routing of the wiring harnesss:-

Bundle connectivity check:-

Application of protection covering:-

Prepare to flatten the view for the wire harness:-

Drafting of the wire harness:-

Conclusion:-

• The wire harness has been designed for the given tailgate assembly and the flatten view is drafted.