Project 2

OBJECTIVE:

Route the Wiring harness on Given car body and Prepare flatten view drawing on CATIA V5 .Application of all Packaging rules, Industry best practices studied in the course shall be demonstrated in design .Apply Protection coverings as required.

Prepare and Submit all necessary reports like clearence,Clipping/Clamping selection, Harness fixing requirements, Harness continuity.

Rules or Assumption to be followed while Routing the Wiring Harness.

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.

CONNECTOR USED IN WIRING HARNESS:

INTERCONNECTION CONNECTOR

12 POLE CONNECTOR:

First we have to download the CAD data from the given link or from www.te.com.

After that define the Component Electrically .

STEPS:

Steps to be followed to define the component Electrically .

1. First made Bundle Connection Point. .

2.Then made Connector Connection Point.

3.Then define the component as Connector with the help of define connector command .

4.Then define the Bundle Connection Point with the commanddefine Bundle Connection Point.

5.Then define the Connector Connection Point with the help of Connector Connection command .

These Steps are shown in the pictures below. 

We have to follow same steps for all the component.

 

4 POLE CONNECTOR:

Used for the Wiper Motor.

2 POLE CONNECTOR:

Used for the Boot lamp and for the Tail lights.

WIRING HARNESS ROUTING AND PACKAGING 

HOW TO ROUTE THE WIRING HARNESS:

First make a new product and name it as Assy Wiring harness Context.

Then add the Given car body in the context.

After that add new product in the context and name it as the Wiring harness Geometrical Bundle.

Then add the Connectors and the clips and clamps we wanted, and position all the connectors and clips and clamps where we want them to be placed.

Then define the product of the Assy Wiring Harness Geometrical Bundle electrically. We can do it by the command Geometrical Bundle.

Now go to the Wiring Harness assembly, And go to the multi branchablke command then a muti branchable is added , and then go the Bundle Defination, and select the interconnection connector and then select the furr tree clip.

Then go to Branch defination and go to the route defination and choose the bundle which is previously made and then choose the another furr tree clip or the component in which we want to route the wiring .

And then follow the same previous step. 

And do it tilll the Wiring harness is completed.

Wiring harness is shown below in the pictures.

Components of Back door to be Wired.

Interconnection Connector.

Below picture shows the Left Hand side Tail light.

Connector shows the Wiper Motor .

One connector shows the Boot lamp and other shows the Right Hand side Tail light.

HOW COT TUBES ARE APPLIED.

Go to the Protective command , as shown below.

And now Select the folder of catalouge and then.

Choose the COT TUBES which we want to add on Bundle Segment .

Now choose the Bundle Segment on which we want to add the Protectice covering.

And now give the Start or End extremities. If we want to give

I have given the 20mm Extremities from the Connector side.

The pictures below show the procedure to apply COT TUBES.

CHECKING OF BUNDLE SEGMENT CONTINUITY

HOW TO CHECK THE BUNDLE CONTINUITY:

Go to the Edit Tab and now go to the the search command . and choose the elctrical workbench , bundle segment type and choose the fully connected in hte attributes.

Now search it.

FLATTENING:

First make a new product .

And then define the Flattening Parameters.

And now Extract the bundle .

And now flatten the Bundle as shown below with the Flatten Command.

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DRAWING 

HOW TO MAKE DRAWING:

Go to the new product and choose Drawing.

And now choose the front view command and select a plane and get the front view. As shown below.

We an also change the properties from the Flattening parameters and also from the view properties.