Project 2

Objective:

To route the wiring harness on the given tailgate assembly and prepare the flatten view drawing in CATIA V5.

Input data:

Assumptions:

1. Provide clips/clamps as per requirement.
2. Make sure that there is no any fouling case while designing the wire harness. Additional clips/clamps may be used to avoid fouling case.
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 away the harness from heat generation components.
6. Protection should be provided as needed according to surrounding temperature.
7. Branch length should be greater than 50mm.
8. Minimum distance between two branch points should be at least 50mm.
9. Minimum distance between clip and 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. While using dummy connectors, ensure that whatever positions you are defining that are practical. Bundle diameters and another placements can be defined properly for the wire harness routing.
13. If the packaging area is too tight and there are many packaging constraints then we can think of creating harness channel which can be used to route and protect the wire harness effectively.

Routing the 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

1.interconnection connector:

2. 2 pole connector used for light:

Clip and clamp is used to set the location of wire:

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

Steps for routing:

1. First Defining all the connectors as electrical components and the clips as the supporting equipment.
2. Locate all the connector , clip, and cavity at the desired location.
3. Now by using multi-branch bundle route all the connector with the clip and clamp
4. By create a catlouge and add the protection cover od 15mm diameter and 8 mm diameter.
5. Now by using protection covering tool , protect all the bundle.
6. Create a gap from the end and start extremity by 10mm or 20mm.

Flatten view :

Harness assembly of back Door: