Project 2

% Routing the wiring harness on the given Backdoor and preparing flatten view drawing in CATIA V5.

% Downloading the backdoor CAD file and defining the necessary connectors and clamps.

• First we download the backdoor file and all the CAD files from the links provided in the challenge.
• Next we define the connector and p clamp electrically.
• Next we define the connector geometrically in part design by making one point at the centre of the bundle entry side's face and making an axis at the centre of the connector connection side's face. Axis orientation should be as follows x-axis should point towards the locks on the connector, the y-axis should be normal to the surface and the z-axis should either point up or down.
• Next we define the connector electrically in the electrical part design. First, we click on define connector, select the respective connector, and write a number of terminations according to the connector. Next, we define the bundle connection point by selecting the point on the bundle entry side and define the connector connection point by selecting the axis.
• Next we define the P clamp using the points and planes method.
• Now all the required components are defined.

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% Creating a catalogue

• First we create a catalogue by clicking on file>New part>Catalogue document.
• While creating a catalogue we named the family Backdoor_electrical_parts and selected the type as electrical and saved it.
• Next we added the electrically defined connector and P clamp in the catalogue.

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% Manipulating the connectors and p clamps to place them on the backdoor.

• First we copy-paste the backdoor file to a new product file.
• And add two different product files for tail light wire harnessing and license plate wire harnessing because we need to create 2 different multi-branchables.
• We manually place the components on the back door for the tail light and license plate separately, we cant snap because of the uneven surface.
• After placing the connectors and p clamps we go for wire routing.

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% Creating bundle segments

• Now we switch to electrical harness assembly workbench to create routings and branchable points.
• First we have to define the mechanical product (Tail light and License plate) as an electrical product to create bundle routings so we use the geometric bundle command and then select the product name on the tree structure.
• Now we can route the bundles and create branch points as we need.
• While branch definition process we select the main branch as 10mm and bend radius as 15mm(1.5*diameter) and slack 0.

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% Checking bundle continuity

• Press ' ctrl+F ' > Search > Advanced. Select workbench as electrical, type bundle segment and attribute as fully connected.
• Select query as true to show all the connected bundle segments, and we can select false to show all the bundle segments which are not connected.
• We have to check bundle continuity for both the multi-branchables separately.

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* For multi-branchable 1

* For multi-branchable 2

% Flattening the harness assembly

• First we open a new product file in the electrical harness flattening workbench and add flattening parameters using the harness flattening parameters command.
• Next using the extract command we open our wire harness assembly (first tail light) created above in the product file where we have added flattening parameters.
• Next we use flatten command to flatten the assembly by selecting the active plane.
• We can use the same process for the license plate as well or we can add both assemblies to on flattening file but we made 2 different files.

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% Placing the flattened view on a drawing sheet

• Now we open a new drawing sheet by pressing ctrl+N and selecting type as drawing.
• We select sheet properties and change the scale to 1:3 for the tail light and 1:2 for the license plate to fit the flattened view on the drawing sheet.
• Next we select the front view and then open our flattened harness product file and select the face which we selected for the flattening process. Then it is opened on the drawing sheet.
• Now we need to add the frame, title, and bill of material.
• We can add a title by clicking edit > sheet background and then frame and title.
• To add a bill of material we click on insert > generation > bill of material > bill of material.
• We made 2 different drawing sheets for tail light and license plate.

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* For tail light

* For license plate