Project 2

The given Backdoor CAD model is downloaded and the available 3D connector, clips and protective coverings models from the previous challenges are used.

Images were refered for the idea of routing for the backdoor.

So mainly two separate routings were needed as per current and voltage requirements of the electrical lamps used.

Therefore one routing from the inter-connection point to the tail lamps and the other routing from inter-connection point to the number plate lamps.

2-pole connectors and 3-pole connectors have been selected for number plate lamps and tail lamps respectively.

Wire with diameter 5mm is considered and same compatible fir-tree clip is selected for mounting purpose.

The procedure followed is similar to project-1, but here two individual harnesses are created for separate routings.

The clearance provided between base plane and the resting face of the clip is 2mm.

Easy removable fir tree clip is selected which will be helpful in service and maintainence of the harness.

The clips are mounted approx. 200mm at regural intervals as per packaging rules.

Where ever bends are present in routing care is taken to provide mounting before and after the bend as per packaging rules.

minimum branch length of 50mm is maintained.

minimum distance between two branching points is not less than 50mm.

Protecting coverings like corrugated tube and tapes have been applied as per requirement with 30mm of end extremity.

Care has been taken to avoid interference between the harness bundle and the surrounding data or the backdoor part. Overlapping of the harness bundles are also rectified.

Necessary slack is provided for the smooth routing of the harness bundles and to minimize the tension on the bundle.

Since it is a backdoor which is subjected to opening and closing, the slack provided is considered based on the open and close conditions.

Wiring Harness Routing: Number plate lamps

Wiring Harness Routing: Tail lamps

Complete Wiring Harness for Rear Door

Bundle Continuity Check

Wiring Harness Drawing: Tail lamps

Wiring Harness Drawing: Number plate lamps

Due to the presence of two separate harness geometrical bundles, two individual drawings have been created with single line representing the wire bundle and the double line representing the protecting coverings for the same.

All the CAD product file with context assembly, flattening, drawing are attached.