TAILGATE WIRING HARNESS DESIGN

Uploading Zip file B. Including JPG format.

Project 2 - TAILGATE WIRING HARNESS DESIGN

AIM - Route the wiring harness on given tail gate and prepare flatten view drawing in CATIA V5.

OBJECTIVE -

• Route the wiring harness on given car body and prepare flatten view drawing in CATIA V5.
• Prepare flatten view drawing in CATIA V5.
• Apply all packaging rules, and industrial best practice.
• Apply protection coverings as required.
• Provide all necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity, assemptions if required.

Packaging rules and assumptions made in this project -

• Avoid harness routing and clipping in blind zone.
• Provide additional slack to the harness according to the surrounding 5-10% of slack is enogh.
• Provide enogh clearnace to the wiring harness with the respect to the surrounding.
• Provide guide channel if required.
• Use available holes for clamp and clip mounting.
• Enough clamps to be provided to ensure positive clearance with surrounding and safety of wiring harness.
• Distance between two clamps on straight branch should be maximum of 200mm.
• Use rubber grommet which provide proper sealing, protect harness from sharp edges, provide protection against vibration, and even act as a clamp.
• branch length should be minimum of 50mm.
• Minimum distance between clip and nearest branching point should be 25mm.
• Minimum distance between two breakouts should be 50mm.
• Limit the number of branches from single branching point to 4.
• Provide bracket for interconnection connector parking.

1. Download car body model on which wiring harness to be routed.
2. Creating context assembly.
3. Define electrical devices in electrical part design module.
4. Define interconnection connector ( C-776438).
5. Define connectors used for lights ( C-DTM-04-2P).
6. Design and define clips and clamps to be used for wiring harness.
7. Clips used for this model are (PC Series) PC-14-PA66-BK, PC8DP7S-PA66-BK, PC5DP7S-PA66-BK.
8. Define clips as electrical support.
9. Adding all electrical equipment in geometric bundle assembly. (Clips are assembled on the inner panel, which is then be coverd with plastic trims)
10. Two EDGE GROMMETS are used in this model as edge protection.
11. Edge guard strip is used to protect wire bundle from sharp edges.
12. Bundle segment, branch defination.
13. Bundle protection.
14. Electrically harness flattening.
15. Final rendered view of wiring harness design for Car Tailgate.