Project 2

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.

Aim: To route the wiring harness to the given tailgate assembly and prepare the flattened view drawing in CATIA V5.

Given backdoor:

Assumptions -

1. Provide clips/clamps as per requirement.
2. Make sure that there is no falling case while designing the wire harness. Additional clips/clamps may be used to avoid falling cases.
3. Give additional slack if needed. 5-15% slack is sufficient.
4. Avoid routing on sharp edges or else provide protection over the harness.
5. Follow the clearance distance and keep the harness away from heat generation components.
6. Protection should be provided as needed according to the surrounding temperature.
7. The branch length should be greater than 50mm.
8. The minimum distance between the two branch points should be at least 50mm.
9. The minimum distance between the clip and the branch point should be at least 25mm.
10. Avoid too many sheet metal brackets on the engine.
11. The wiring harness should be easy to assemble and easy to access.
12. When using dummy connectors, ensure that whatever positions you are defining is practical. Bundle diameters and other placements can be defined properly for wire harness routing.
13. If the packaging area is too tight and there are many packaging constraints then we can think of creating a harness channel that can be used to route and protect the wire harness effectively.

Routing to Wiring Harness:

1. First, we have to consider the components we need for the routing. Here we are only considering the taillights and the number plate lights.
2. Here we are considering 2 different types of connectors as follows
3. Interconnection connector

Pole connector used for light

Clip and clamp are used to set the location of the wire

The Fir tree clamp is used for 5mm dai and p clamp is used for 10mm diameter

Steps for routing:

1. First Defining all the connectors as electrical components and the clips as supporting equipment.
2. Locate all the connectors, clips, and cavities at the desired location.
3. Now by using a multi-branch bundle route all the connectors with the clip and clamp
4. By creating a catalog and adding a protective cover of 15mm diameter and 8 mm diameter.
5. Now, by using the protection covering tool, protect the whole bundle.
6. Create a gap from your end and start the extremity by 10mm or 20mm

Wire Flattening:

Drawing sheet: