Project 2
BOOT DOOR WIRING HARNESS CREATION:
1. Context Assembly:
Create a product file as a context assembly and name it "Assy. Boot Door Harness Context".
2. Import Background:
The CAD file of the Boot Door is provided as background for the wiring harness. Import the CAD file into the context assembly.
3. Preparing Background:
Since this harness should be designed inside the door channel, The outer panel of the door was hidden for convenience.
4. Create Boot Door Harness Geometrical Bundle:
A product file is created into the context assembly as Geometrical Bundle and named "Assy. Boot Door Harness Geometrical Bundle".
i. Define Connectors Electrically:
Define all the required connectors electrically.
ii. Clamps:
Define Clamps electrically which can be used for routing the bundle.
Sticky clamps are used for the entire routing and packaging because of the practical difficulty of using other clamps.
iii. Import & Locate Clamps:
The above-defined clamps are imported into the geometrical bundle and located as per the packaging and routing practices used in the industry.
iv. Eelctrical Components:
The electrical components which are available in Boot Door are considered during the design of harnesses.
a. Interconnector:
The Boot door harness will be attached to the main harness using a 12-pole interconnector.
b. Tail Lights:
The tail light will be available on both the right and left sides of the door. a 4 pole connector is provided for the same.
c. Reverse Camera:
The reverse camera will be fitted to the boot door. A 4-pole connector was provided for the same.
d. Wiper Motor:
The wiper motor for the rear wiper will be fitted in the boot door. A 2-pole connector is provided at the location for the same.
e. Number Plate Lights:
The number plate lights will be fitted in the boot door. A 2-pole connector is provided at the location for the same.
f. Door Ajar Sensor:
The Door Ajar Sensor will be fitted at the bottom of the boot door. A 2-pole connector is provided at the location for the same.
g. Boot Door Switch:
The Boot Door Switch will be fitted into the boot door. A 2-pole connector is provided at the location for the same.
v. Grommet:
A rubber grommet is used to let the harness pass through the door channel from outside to inside and also will protect the harness from damage from the sharp edges of sheet metal in BIW.
Oval Rubber Grommet:
The oval-shaped rubber grommet is designed and defined as a supporting equipment.
The above-defined grommet is located on the desired location.
vi. Location of Connectors & Clamps:
All the above-mentioned connectors, clamps & grommets are placed in the desired locations
vi. Creating Wiring Bundle:
Create a wiring bundle from the interconnector to the various connectors with the appropriate routing and bundle diameter size. Multiple branching points were taken for appropriate routing and positioning. Required slacks were provided in a few bundles.
viii. Channel Lid:
the channels provided were covered with their counterparts to ensure that the harness stays within the channel.
Thus the Boot Door wiring harness is successfully routed with the application of all Packaging rules and Industry best practices.
5. Flattening of Harness:
i. Create a product:
Create a product file and name it "Project 2 - Boot Door Wiring Harness Flatterning"
ii. Defining Flattening Parameters:
The flattening parameters were created by selecting the "Harness Flattening Parameters" tab in Electrical Harness Flatenning Workbench.
The following parameters are selected in the Harness Flattening Parameters window > General Tab
The following parameters are selected in the Harness Flattening Parameters window > Flattening Orientations Tab
The following parameters are selected in the Harness Flattening Parameters window > Flattening Scaling Tab
The following parameters are selected in the Harness Flattening Parameters window > Synchronization Tab
The following parameters are selected in the Harness Flattening Parameters window > Link Tab
The following parameters are selected in the Harness Flattening Parameters window > Drawing Tab
iii. Import the product file:
The product file to be flattened are imported by selecting the Extract command from the "Electrical Harness Flatenning" workbench.
iv. Flatten the Harness:
Flatten the imported wiring harness by selecting Flatten command.
v. Arrange Flattened Harness:
Rearrange the flattened harness bundle to the desired positions.
vi. Save the file:
Save the product file to the desired location.
6. Creating Drawing File:
i. Create Drawing File.
Create a new drawing file by selecting New > Drawing. Choose Standard as ISO & Sheet Style as "A0 ISO".
ii. Add title block:
Add title block by selecting Edit > Sheet Background. Apply a Title block by selecting the "Frame & Title Block" command. Exit the Sheet Background workspace by selecting Edit > Working Views.
iii. Add Drawing:
Add a drawing of the product file by selecting Front View Command from Drafting Workbench. Select a surface from the product file window. Orient the harness as required using the manipulation tab.
iv. Annotation:
Add annotations to the drawing as per requirement using "Text With Leader".
v. Bill of Material:
Create a bill of material for the drawing using the following command, Insert > Generation > Bill of Material > Bill of Material.
vi. Final Drawing:
The final drawing of the flattened harness is created.
vii. Save file:
Save the file in the appropriate location.
Viii. Save the file as PDF:
The wiring harness drawing is saved as a PDF by selecting File > Save As.
7. Final Report:
i. Clearance:
During the design of the Wiring Harness for the Engine, Appropriate clearance was provided in all possible situations as per industry standards.
ii. Clamping:
Sticky Clamps were used to carry the main bundle since it will be easy to route the harness and also maintain proper clearance.
iii. Bundle Connectivity:
The designed harness is checked for bundle connectivity.
8. Attachments:
All the components and files used are attached as a single compressed Zip file.