Project 2

REPORT

Aim:

To route the wiring harness on the given tailgate assembly and prepare the flaten view drwing in catia v5

OBJECTIVE: The objective of this project is to route the wiring harness and prepare flatten- view drawing for the given car body hatch. all types of pacakaging rules and constraints have to be considered while routing the harness. industry best practices should be implemented in the harness design. all necessary details like clerance/ clamping selection, harness fixing requirements, harness continuity should be provided in order to design the wire harness.

DESIGN CRITERIA AND PACKAGING ASSUMPTIONS:

• Wiring harness routing shall provide ease in manufacturing,accessibillity, easy removal, and easy maintenance of attached equipment and wiring harness.
• Routing throught small structural holes and openings shall be avoided, minimize chaffing and handling of the wire harness during installation
• Avoid the harness routing and clipping in the blind zone of the operator during assembly or in service.
• Routing shall offer protectionagainst possible damage through common miuses such as being handhold and temporary support for test equipment.
• provide additional slack to the harness according to the surroundings and harness bending requirements
• Ensure the routing meets the clearance requirements with different surrounding parts.
• Avoid routing over the bolt, near to the bolted joints.it may damage the harness or puncture the harness. keep harness away from panel mounting screws.
• Avoid harness routing near sharp edges, if not possible provide protection to the harness.
• The maximum distance between two clips on a straight branch is above 50mm.
• Provide clips and clamps if the harness is going to bend at multiple locations.
• The use of too many sheet-metal brackets should be avoided.
• The branch length should be more than 50mm.
• Min distance between clip and branching point to be 25mm.
• Min distance between two branch breakouts should be 50mm.

CONTENT-

STEP1-Creating context assembly

A context assembly has to be created which will serve as the main assembly for the car back door. The context assembly will contain the 3D-CAD data for the car body hatch and the car body harness geometrical bundle.

STEP2- Defining 2-pole connector electrically

The 2 pole connector used for this harness assembly . The CAD data for this connector was downloaded from Te.com. To define the connector electrically we should define the geometrical parameters, bundle- connection point, and the geomtrical parameters, bundle- connection point, and the connector-connection point for the downloaded connector.

STEP3- Adding connectors to the 2 tail lights and 2 license plate lights

All the 2-pole connectors are added inside the body harness geometrical bundle assembly. Manipulation tools along with a compass, snap and smart move features should be used to locate all the 4 connectors in their desired locations. These connectors are shown in orange color for clarity.

STEP4- Defining and locatiing interconnection connector

A 12-pole c-776438-4 connector and mounting cavity c-is used as an interconnection connector. The 3-D CAD data file for the required connector and the cavity is downloaded from te.com. Both the connector and the cavity are electrically defined and mounted near the already present slot on th car body hatch as shown below.

STEP 5 - Defining clip mounts as supports

For the mounting solution, we will be using hellermann tyton push- button cable tie mounts and Bundling clips with fir tree clips. Both the clips were modeled using the dimensions given by the manufacturer. These clips have to be defined as support. To do so we have to defined geometrical parameters and bundle entry and exit points from both left and right sides of the clips.

STEP6- Bundle Routing

we will start bundle routing from the interconnection connector. The bundle diameter for the main trunk is assumed to be 20mm. The bundle diameter leading to the four 2 pole connectors is assumed to be 5mm. Bend ratio is assumed to be 1.4 and slack value between 1-10% is used wherever needed.

STEP8-Checking Bundel continuity.

First, we have to make sure that the multi-branch able is selected then have to go in EDIT.

Selecting the TRUE option will show all the connected bundle segments while selecting the FLASE will show all the non-connected bundle segments.

For now, we will select TRUE and search for results. all the bundle segments are highlighted and found showing that all the bundle segments are electrically connected.

STEP9- Create flat-pattern of wiring harness bundle

To make a flattened view of any wiring harness we should be working in the electrical harness flattening workbench of CATIAV5. we should also make sure that the flattening file is saved in the same folder where we have all the parts of the harness assembly

While defining the harness flattening parameters make sure to use the single line for the bundle segment and double line for the protective covering.

Extract and bring the bundle assembly in to the car body flattening product file and then flatten the harness along the xy plane.

STEP10- Creating a flatten-drawing view for the wiring harness assembly

Make a new drawing file and defined all the necessary drawing parameters. insert the front- view of the harness assembly into the drawing file.

Define drawing properties as shown below. it should be noted that for the dres-up settings 3D wir frame is always ON. if this setting is not selected then the bundle segments will not be visible on the drawing view.

CONCLUSION-

Routing of the wiring harness for the car body hatch assembly was done and the flatten-view drawing was prepared in CATIA -V5. Various packaging rules and condtraints werwe considered while routing the harness, industry best practices were considered while routing the harness. industry best practices were implemented in the harness design. All necessary details like clamping selection, harness fixing requirements, harness continuity were provided in order to design the wiring harness.