Project 2

PROJECT- 2

Aim: Route the Wiring Harness on given Car body and prepare flatten view drawing in Catia V5.

Statement of assignment:

Route the Wiring harness on Given car body and Prepare flatten view drawing in CATIA V5. Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required.

Available connector 3D data can be used, or you can download the connectors from www.te.com

Prepare & Submit all necessary reports like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity, Assumptions if any along with CATIA 3D data.

BACKDOOR:-

Assumptions:

The wiring harness packaging rules and the industry best practices that have to be followed to complete this project are as follows:-

1. Easy manufacturing, installation, removal, and maintenance have to be considered while designing the wiring harness.

2. Routing through small structural holes or opening shall be avoided to minimize chaffing and handling during installation.

3. Avoid harness routing and clipping in the blind zone or hard to reach areas during harness assembly or in service.

4. Provide additional slack if needed according to the surrounding and harness bending requirement. For this project, the slack value between 1-5% is used.

5. It should be made sure that there is no case of fouling while designing the wiring harness in the CAD environment. Additional clips/ clamps may be used to avoid fouling.

6. Avoid harness routing near sharp edges or else provide protection over the harness.

7. Enough mounting equipment such as clips and clamps should be provided.

8. The branch length should be greater than 50mm.

9. The minimum distance between the clip to the branch point should be at least 25mm.

10. The minimum distance between the two branch points should be at least 50mm.

11. The wiring harness should be easy to assemble and easy to excess.

12. Clips/ clamps used for the wiring harness should be easily available in the market to avoid extra cost for custom mounting solutions.

Lets Design wire harness of Back Door:-

First lets create Back-door Context Assembly-

Then add Backdoor Assembly and Geometrical Bundle in our context Assembly-

Now we will define all components as Electrical components.

C-DT06-6S

C-DT-06-4S

FURR TREE CLIP

P-CLAMP

Now We will place all electrical devices at desired location on backdoor

Lets do routing of harness bundle:-

we will start the routing from interconnection connectors:-

We have to provide Protective cover on our wire Bundle to Addictive Strength:-

We will use COT tubes for covering purpose.

Our routing will look like-

We will check our Bundle Continuty before flatening-

Now we will create a new product in Wire Harness Flatening Workbench and name product as Backdoor Harness Flatening Assembly

Define Parameters for Flatening surface-

Useing Extract command in flatening workbench we will extract our Geometrical Bundle-

Use Flatten command to flate our Geometrical Bundle:-

Now we will create a sketch and using front view command we will draw the sketch of our Back-Door Flatening Assembly:-

CONCLUSION:
The wiring harness has been designed for the given tailgate assembly and the flattened view is drafted.