Project 2

AIM:Route the Wiring harness on Given car body and Prepare flatten view drawing in CATIA V5.

Objective:The routing of the backdoor of the car is done in this particular challenge, by considering all industrial standards and procedure.The flattened view and its 2D representation needs to be done in this challenge.Industry best practices should be implemented in the harness design. All necessary details like clearance/ clamping selection, harness fixing requirements, harness continuity should be provided in order to design the wiring harness.

Key aspects for the packaging and routing:

1. The most important consideration prior to any step is to thouroughly observe the design for which routing needs to be done, we must be aware of the basic input like types of connectors used for routing, the usage of the clamps etc.
2. The placing of the connectors need to be very precise as, this decides the routing length and even extreme level the routing can be done without fouling.
3.  Easy manufacturing, installation, removal, and maintenance have to be considered while designing the wiring harness.
4. Routing through small structural holes or opening shall be avoided to minimize chaffing and handling during installation.
5. Avoid harness routing and clipping in the blind zone or hard to reach areas during harness assembly or in service.
6.  Provide additional slack if needed according to the surrounding and harness bending requirement. For this project, the slack value between 1-5% is used.
7. The routing must be done by maintaining the safe distance from the heated compartment like exhaust pipe and engine cylinder (150mm-200mm in general).
8. The branch length should always be maintained greater than 50mm throughout the routhing bundle.
9. The sack of minimum 5-10 percentage can be provided .

Routing parameters provided:

Here for the car body backdoor routing, i have used 2 four pole connectors and 1 two pole connector , fir tree clip for positioning of the bundle.Two four pole connectors are used for the tail lights and 1 2 pole connector is used for the number plate lights.

The bend ratio for all the bundle segments is considered to be 1.4

1)STEP1: CONTEXT ASSEMBLY

Firstly create the context assembly in assembly workbench and then add two products in it, one is the 16V engine for routing purpose and other one is the geometrical bundle assembly for adding the components and creating the multibranchable, and define the geomertical bundle assembly as multibranchable in the electrical harness assembly.

2)STEP2 : ADDING COMPONENTS INTO GEOMETRIC BUNDLE ASSEMBLY

Now start adding the connectors into the geometrical bundle product file but prior to this make sure connector is electrically defined :define the sensor electrically ,i.e the 4 pole connector for the placing of next to the fuel injectors, this can be done with the help of part and electrical part workbench.The 4-pole connector used for this harness assembly is "C-156389-1". The 3D 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 connector-connection point for the downloaded connector.

3)STEP 3 : FOUR POLE CONNECTOR

Position the 4-pole connector at the two tail light  sensor position, you can simply make use of the manipulation toolbar & compass  tool in the assembly workbench.

4)STEP 4- TWO-POLE CONNECTOR

The next step is to place the other 2-pole connector on to the number plate light sensor, firstly you need to define the connector electrically by defining it as a connector with two terminals and later defining its connector connection point and bundle entry point .

5)STEP 5- INTERCONNECTION CONNECTOR

The next step is to assign the position for the inter-connection connector, this connector takes in the input of the various connectors with its 12 poles and lends the output to the ECU that takes the respective responses.In our design we will consider that input from the top roof of the care comes from the top  side so it will be easy for us to connect it with inter-connection connector rather it will also reduce the length of the bundle because placing the connector on left side will ultimately extend the path followed by the roof harness.

backdoor view with all the components which includes 3 total connectors,  , 1 interconnection connector, 3 P-Clamps, 2 fir-tree clips .

STEP 9: ROUTING FROM THE INTERCONNECTION CONNECTOR.

We start our routing from the interconnection connector with bend radius ratio as 1.4 and bundle diameter as 10mm, and adding sack where it is required .

The main bundle of our routing connects the interconnection connector ,3 fir tree clips  and one 4 pole conector used in tail light. .

After that add the fir-tree clip or connecting the branch from the main branch towards the number plate sensor and the other tail light sensor and this can be done by introducing the branch point in the main bundle and later defining the routing from from branch point to the fir-tree clip.

STEP 10- PROVIDING THE COT TUBES.

We need to add the cot tubes from our catalog by using the protective covering toolbar in electrical wiring harness assembly , or you can create the new cot tubes into the electrical part workbench. The defined cot tubes over here have given different colour codes.

YELLOW -MAIN BRANCH.

BLUE - SUB- BRANCH CONNECTING  CONNECTORS AND FIR TREE CLIP

Same procedure have follow for Plate light From Step 1 to 10. As mention color code green for COT tubes.

STEP 10-CHECKING BUNDLE CONNECTIVITY

Now we need to check the connetivity of our bundle and this can be done by using the edit-search-advance-electrical-bunddle segment-fully connected, make a search for the all connectivity to be true.

STEP 11- FLATTENING AND DRAWING

To make a flattened view of any wiring harness we should be working in the Electrical Harness Flattening workbench of CATIA V5. 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.

Now set the flattening parameters without which you wont be able to use any flattening workbench toolbar.

By using the extract toolbar add the geometrical bundle inside the flattening assembly.

Use the rotate, blend , and tools to get the desired orientation.

lastly you can go to the drafting workbench and selecting the same guiding channel face as front vie plane add the flattend view in drawing , and set the 3D wireframe as always visible in order to get the differentiation between the cots and bundles and even to get your bundles represented in the drawing .