Challenge

Project 2

SShobhit Nautiyal6 Aug 2022

DESIGN

WIRING HARNESS ROUTING ON CAR BACKDOOR ASSEMBLY

AIM: Route the Wiring harness around given context environment of a car backdoor/tailgate assembly.

OBJECTIVE:

Route the wiring harness bundle around the car backdoor assembly.
Flatten the Geometrical bundle in Wiring Harness Flattening workbench and prepare the drawing of the flattened view in drawing workbench.
Follow and apply the proper designing and packaging rules and industry best practices.
Apply protection covering as per requirement.
Providing all necessary details like clearance, clipping/clamping selection, Harness fixing requirements , Harness continuity, Assumptions if required.

DESIGN CRITERIA AND PACKAGING RULES AND ASSUMPTIONS:

Wiring harness routing shall provide ease in manufacturing, accessibility, easy removal, and easy maintenance of attached equipment and wiring harness.
Routing shall offer protection against possible damage through common misuses such as being handhold and temporary support for test equipment.
Avoid the harness routing and clipping in the Blind Zone of the operator during harness assembly or in service.
Routing through small structural holes and openings shall be avoided, minimize chaffing and handling of the wiring harness during installation.
Avoid routing over bolts, near to the bolted joints. It may damage the harness or puncture the bundle. 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 200mm.
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.
Minimum distance between clips and branching point should be 25mm.
Minimum distance between two branch breakouts should be 50mm.
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.
Provide bracket for interconnection connector parking.
Limit the number of branches from single braching point to 4.
Provide guide channel if required.
Use available holes for clamps and clip mounting.
Use rubber grommet which provide proper sealing, protect harness from sharp edges, provide protection against vibration and even act as calmp.