Project 2

BACK DOOR WIRE HARNESS ASSEMBLY

project is to route the wiring harness and prepare flatten view drawing for the tailgate of the car. All types of packaging rules have to be considered while routing the harness and industry based practices shall be demonstrated in harness design. All necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design the wiring harness.

BACKGROUND, TECHNICAL SPECIFICATIONS &ROUTING

GIVEN BACK DOOR OR TAILGATE DATA:-

Assumptions:

1. Wiring harness should be routed in such way that it is easy to assemble and access.
2. Easy manufacturing, installation, removal and maintenance have to be considered while designing the wire harness.
3. Wiring Harness should be kept away from sharp environment like edges, corners etc.
4. Avoid harness routing and clipping in the blind zones or hard to reach areas during harness assembly or service.
5. Provide additional slack if needed according to the surrounding and harness bending requirement. If harness is passing through the closures/doors or tail gates then envelope dimensions during opening and closing of doors shall be considered to provide the slack. Check the harness slack requirements with open and close conditions to avoid excess slack.
6. Routing through small structural holes and openings shall be avoided. To minimize chaffing and handling of the wiring harness during installation.
7. It should be make sure that there is no case of fouling while designing the wiring harness in the CAD environment. Additional mounting equipments like clips/clamps may be used to avoid fouling.
8. Use of rubber grommet is recommanded if harness is passing through sheet metal panels. Example- firewall, passing to door, tail gate etc.
9. The branch length should be greater than 50mm.
10. The minimum distance between the clip and branch point should be at least 25mm.
11. The minimum distance between the two branch points should be at least 50mm.
12. Clips/clamps used for the wiring harness should be easily available in the market to avoid extra cost for custom mounting solutions.

Creating Context Assembly:-

1. We have created context assembly for the tail gate of the car as main assembly as shown in above figure.
2. This context assembly contains the 3D cad data for the tail gate of the car and car tail gate harness geometrical bundle.

Difining 4-pole connectors electrically:-

• Here, we will use 4-Pole connectors for this assembly and for that we have downloaded these connectors from TE.Com
• We should have to define it electrically that is to define geometrical parameters, bundle connection point and connector connection point.

Defining and locating interconnection connector:-

• A 12-pole is C-776438-4 used as an interconnection connector and "C-1924487-2" as mounting cavity.
• The 3D CAD data files for interconnection connector and cavity are downloaded from TE.com

Defining fir tree clips as support:-

• We will be using fir tree clip for the mounting purpose.
• We have to define geometrical parameters, bundle entry points and exit points from both left and right side of the clip.
• We have defined these clips electrically as a support in Electrical Part Design workbench as shown in below figures.

Mounting the FIR TREE Clips and Placing the Connectors:-

Bundle Routing:-

1. The bundle segment is routed from the interconnection connector to the Omega clips and guided towards the 4 and 2 Pin connectors. while maintaining the Bend radius ratio of 1.4.
2. We have used bundle thickness 5mm

Adding protective coverings to harness bundle:-

Here is the below figure, we have done with the whole wiring harness routing for the Backdoor. Now, we have to add protective coverings to all bundle segments

Checking bundle continuity:-

In this step, we must first ensure that multi-branch capability is selected before proceeding to Edit>Search>Advanced>Workbench-Electrical>Type-Bundle Segment>Attribute-Fully Connected.

Selecting 'True' displays all connected bundle segments while selecting 'False' displays all non-connected bundle segments.

In this case, we chose the 'True' option and searched for results. As shown in the figure below, all of the bundle segments are highlighted, indicating that they are all electrically connected.

Creating flatten view of the Backdoor Wire harness geometrical bundle assembly:-

In this step, we will use Catia V5's Electrical Harness Flattening workbench to create a flattened view. We should also ensure that the flattening file is saved in the same folder as the other harness assembly files.

1. The bundle assembly was extracted into a Back door wire Harness Flattening Product file, which was then flattened along the face of the interconnection connector.
2. We developed a flattened view.
3. we must rotate bundle segments connecting to the four cam-shaft connectors using the 'Rotate' feature of the flattening workbench.
4. It should be noted that the 'face' of the interconnection connector serves as the flattening plane, so we must rotate the bundle segments only along that plane.

The flattened view's final representation

Creating a flattened view drawing for the wiring harness assembly:-

In the figure above, we're creating a new drawing file and defining all of the required drawing parameters. The front view of the Backdoor wire Harness Flattening Product file must be inserted into the Drawing file. As shown in the preceding figure, we must define drawing properties. It should be noted that the 3D wireframe is always ON in the 'Dress up settings. If this option is not enabled, the bundle segments will not be visible in the drawing view. the Backdoor wire Harness Flattens view's final Drawing view

Routing of the wiring harness for the car tail gate assembly has done and prepared flatten-view drawing in Catia V5. Applied all the packaging rules while routing the wiring harness, implemented industry best practices in the harness design. Also, provided details like clearance, clipping selection, harness fixing requirements, harness continuity in order to design the harness.

BEFORE ROUTING:-

AFTER ROUTING:-