Project 2

Objective:

To provide a concept for a wiring harness for a given tailgate of a car.

Input:

CAD data of the backdoor of a car.

Design considerations and packaging rules:

• Easy manufacturing, installation, removal, and maintenance of the product.
• Routing shall be designed to minimize chaffing and handling during installation.
• Providing required slack.
• No case of fouling while designing the wiring harness in the CAD environment. Additional clips/ clamps may be used to avoid fouling.
• Minimum branch length of 50mm.
• Minimum length between branch points and supports of 25 mm.
• All components can be sourced easily. Avoiding custom parts and assemblies.

For the given tailgate following requirements have been assumed:

1. Terminations for lamps and lights in the back, top, and bottom.
2. Terminations for back A/C vents for defog etc.
3. Terminations for wiper motor.

Therefore the connectors were placed with reference to the above requirements and in locations that are likely to be real-world and final positions after benchmark study on the Dodge Journey.

Conclusion:

The wiring harness was designed, flattened, and depicted as a draft drawing with BOM attached.