Project 2

Dear Team,

Please find the attached Cat Part and images for your reference.

INTRODUCTION:

The trunk or boot of a car is the vehicle's main storage or cargo compartment it also have a hatch at the rear of the vehicle. It is also called a tailgate. These doors can be operated manually or electric powered. here we design the trunk or back door wire harness using the Catia.The Backdoor is an assembly of many parts such as inner panel, outer panel upper, outer panel lower and Reinforcement. Inner panel is attached to the outer panel using mastic sealant.

Types of doors based on working position

1. Top Mounted Door
2. Side mounted Door
3. Bottom Door

Rules to be followed:

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 recommended 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.

STEP 1:

Download the required connectors:

I downloaded the interconnection connector( 12 pole connector ) , 2 pole connector, furr tree clip from the te.com website . after downloading the file , I defined it electrical connector using electrical part design workbench.

STEP 2:

Creating context assembly:

Initialy, we have to create product assembly which includes all the required connectors and clamps and part .It is done by using mechanical assembly design workbench. In this workbench , i placed the connectors and clips on the required position .

STEP 3:

Routing and Packing :

After placing the connectors and clips , I made routing using Electrical harness assembly workbench. Connecting all the connectors and clips and make sure the proper connection by using search option. I checked the bundle connectivity.

STEP 4 :

Packing :

After completing the routing , I create the protecting cover to all the routing path with proper start and end extrimity.

STEP 5:

FLATTENING:

I created the flatening of the wiring harness using Electrical harness flatening workbench.

STE

STEP 6:

Making Flatten drawing :

Created flatening drawing from the flatten harness using drawing workbench.

CONCLUSION:

Thus i have made wiring harness for the tailgate of the car.