Project 2

PROJECT-1

Aim- To route the wiring harness on given Back dore and flatten view drawing in CATIA V5.

Objective- The objective of the project is to route the wiring harness on given Back Dore and prepare flatten view drawing in CATIA V5. All types of packaging rules have to be considered while routing the harness. Also, Industry best practices should be demonstrated in design. All the necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design wiring harness.

Assumptions-

1. Provide clips/clamps as per requirement.
2. Make sure that there is no any fauling case while designing the wire harness. Additional clips/clamps may be used to avoid fauling case.
3. Give additional slack if needed. 5-10% slack is sufficient.
4. Avoid routing over bolt and bolted joints to avoid harness puncture.
5. Avoid routing on sharp edges or else provide protection over the harness.
6. Follow the clearance distance and keep away the harness from heat generation components.
7. Protection should be provided as needed according to surrounding temperature.
8. Avoid direct support for harness on fuel lines routed in the engine.
9. Use plastic guiding channels if needed.
10. Branch length should be greater than 50mm.
11. Minimum distance between two branch points should be at least 50mm.
12. Minimum distance between clip and branch point should be at least 25mm.
13. Avoid too many sheet metal brackets on the engine. Try to use available threaded bosses on the engine or demand for it.
14. The wiring harness should be easy to assemble and easy to access.
15. 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.
16. 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.

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

The first step involved in Wiring harness design process is "Input Collection".
All the required data like Physical Architecture (gives the location of the components), BOM(Bill of Materials), Vehicle Specification (Assembly sequence and Wet/Dry Zones) and ROX(Return on Experience) from past learning.
The next step is "Data Study". The data from the input collection is studied to understand the assembly sequence and component location which helps in building the "Harness Topology".
The Wiring harness topology is reviewed with the cross functional teams it is modified if any changes required.if the topology is approved then the "concept routing" is prepared and it is again reviwed with the cross functional teams to check manufacturing & service feasibility.
After finalizing the concept routing, the packaging requirement is published to the design team and then the proto Harness drawing is reviwed for supplier feasibility. upon finalizing the drawing prototype is built and it is reviewed with all Cross functional teams for validation before releasing the harness drawing to the production.

Download all the relevant CAD data like Back Door, Connectors and clips & clamps etc., for Back Door Harness routing(from Grabcad, TE.com & HellermannTyton etc).

To create the context assembly for routing. Go to File > New > Product and click on OK. Right click on the product and select properties. Name it as "Back Door Wiring Harness Context Assembly" as shown in the below image.

Now add the Back Door 3D Model into the product by right clicking on the product and go to components and select existing component. select the Back Door cad file and click on open.

Since there are two sub systems in our case(Tail tight system and Number plate system) create one Main product named "Back Door_Wiring Harness Assembly" to add the sub systems.
To create the "Back Door_Wiring Harness Assembly" Product, right click on the "Back Door Wiring Harness Context Assembly".Go to components > New Product. Right click on the product, go to properties and name it as "Back Door Wiring Harness Context Assembly".

In the similar way create the sub systems named "Tail light Wiring Harness Assembly" and "Number Plate light Wiring Harness Assembly" under the Back Door_Wiring Harness Assembly as shown in the below image.

Now create Geometrical bundle product named "Tail light Wiring Harness Geometrical Bundle" and "Number Plate light Wiring Harness Geometrical Bundle" under the respective Sub Assembly as shown in the below image.

Before adding the connectors and MOC clips into the geometrical bundle they must be defined electrically. When a component is defined electrially, it can be cross checked with the "icon change" in the specification tree and publications will also be added.

Defining "Moc clips" electrically:
Create the Geometrical parameters like points and planes required for defining the Clip as Support part in the part design module. Now, Switch to Electrical part design module and Use the "Define Support" command .
select the entry point, entry plane, exit plane and base plane. Since there are two possible entries in fir tree cable tie clip use the same command and select the appropriate point and planes to define the other point as bundle entry point.

After Defining all the components electrically, add them in both the geometrical bundle products as shown in the below image. The connectors can also be added from the Catalogue.

In the given Back Door Routing has to be done to the Tail lights and Number plate lights from the interconnect connector at the top.
To the position the connectors and clips and clamps switch to "Assembly design" module an use the " Manipulation, Snap, Smart move, Translation or Rotation" commands as shown in the below image. position the connecors and MOC fir tree clips according to the routing as shown in the below image.

Ensure that the clips and connector postioning is made in consideration of the Design and Packaging rules. Provide sufficient clearance at necessary places to avoid Fouling. Check the whether the minimum distance between the clips are maintained and the distance between two clips on a straight bundle should not be more than 200mm. Also, manufacturing and Service feasibilty has to considered to avoid complexity in production and assembly phase. Routing through small holes and sharp where Chaffing can occur shall be avoided. Do not Route over the fastners or near the fastners as it may damage (puncture) the harness.

To define the Harness assembly electrically, switch to the Electrical harness Assembly module and click on "geometrical bundle" command and then select the "Tail light Wiring harness geometrical bundle" product. After defining the geometrical bundle electrically the icon changes with a blue symbol, you can cross check with the "icon change" as shown in the below image.

First finish the routing of tail light Assembly.The Mutli-Branchable document is created when we start to route the first bundle segment by clicking on the "Branch Definition" command as shown in the below image. Also the module switches to Electrical Harness Installation.
In the Branch definition window, you can set the "Bundle diameter, Bend radius and slack". Bend radius ratio is usually set to 1.4 and it should not be less that that. Always check that the traffic lights near the computed bend radius is in Green. A little Slack is always added to the bundle segment that is connected to the connector to prevent the damage due to tension.
There are various "build mode" available you can also change the mode to length and specify the length of the bundle segment. The bundle segment can also be created along the external curve by clicking on the "external curve" option in the branch definition window and then selecting the curve. This option can be used while routing the bundle inside the Guiding channels.
"Bundle diameter" and "colour" can be changed using "Bundle segmnet definition" option in the branch definition window. When there are various concept proposals Changing the colour using this option helps us to refer quickly during the reviews.
Generally Routing is always started from the interconnects and main trunk is routed first. Then the branch points are created and the bundles are routed from the branch points to the connectors.
Now click on "Route definition" in the branch definition windiow and then select the interconnect first and then MOC clip to route the bundle segment as show in the below image.

you can also add new routing objects in required order by using the "Add before, Add after and replace" options. For example when you select the add before option the new routing objected is created before the selected routing object. similary replace option creates the new routing objects in place of the selected routing object.

Orientation and offset of the bundle segment can be managed by using the "offset management" and "position management" command in the "Route definition" window as shown in the below image.
To change the Tangent orientation you need to select the routing object and then click on "Reverse Tangent" option.
To set the tangential direction similar to an external curve. select the constraint type as "explicit" under tangent managment in the Route definition window.
Automatic option in Offset management is the computer calculated and it the default option. But, when the routed bundle segment is fouling with surrounding the "offset with saftey margin" can be used to provide the required clearance by sepecifying the value. To add the control point in the bundle segment for clearing the clash, Press the control key and place the point appropriately.

Now continue to route the main trunk to the right tail lamp connector through the MOC Clips mounted as shown in the below image.

Now create a "Branch point" in Branchabe-8 by using the "Add branch point" command and select the branchable 8 or directly route a branch from branchable-7 to the left tail lamp connector as shown in the below image.

Now Activate the Number plate light geometrical bundle and Route from the interconnect connecctor at the top to the two connectors at the number plate through the MOC clips as shown in the image.
If necessary, Compass can also be used to th change the orientation of the clips while routing for easy positioning.

Ensure that Slack is added to the bundle segments that are connected to the connectors to prevent damage due to tension.

The protection(corrugated tubes) can be added from the catalogue.
To create CatalogDocument go to File > New > CatalogDocument
Select "Add Family" Command name it as Slit COT and select the type conduit. Then, save it locally.
Now go to File > New > Part and create a single parts as per the names given in the table by using "define protection part" command.
Apply the required Id, OD and thickness. consider the bendlenth as 1.5 times OD. click ok and the tube will appear.
Select the store device command and choose the previously saved catalogue and Slit COT family. click ok.

Using COT tubes of different colours can be helpful in identifying the sub system that harness belons to. It is also selected based on the temperature. Cotton tapes are used at extremely hot zones like engine. Generally battery cables are braded with silica material to offer high protection.

Now Switch back to Electrical harness assembly module and use "Protective Covering" command to apply proctection to the bundle segments. Browse the catalogue, select the COT tube of required diameter and selecct the bundle segments(Use CTRL key to add more bundle segments). click on OK.
you can change the extremity point by clicking on the "start extremity" and "end extremity". specify the ratio or length and click on ok.

TO check the continuity of the bundle segments go to edit > search. click on the advanced tab. select the workbench as electrical, Type as bundle segment and Attribute as Fully connected. select the false option. click on the seach icon and ensure that no objects are found as shown in the below image. You can also select the true option and click on searcha nd select to check whether all the bundles are connected.

Now, Got to File > New > Product and name it as "Back Door Wiring Harness Flattening". Switch to Electrical harness flattening installation and add the flattening parameters by using "Harness Flattening Parameters" command as shown in the below image.
Select the active place and the appropriate representation type in the drawing tab as shown in the below image. Click OK and Save the file in the same location as the context assembly.

Tile the windows vertically and Select the "extract" command and click on the Geometrical bundle product in the Context assembly window to call the harness assembly into the flattening product. Click on "flatten" command and click on any bundle and enable the select all bundle segments option. click on ok.
You can use the compass to position the channel, clips and clamps accordingly. To create links that are created while extraction, use the Auto Update Flatten link , Manually Update Flatten link commands.and to remove links. Also use "synchronize" command to update the 3D changes made in the harness assembly.
Use the rotate, roll, straighten and junction command to change the branch orientation according to the requirement as shown in the below image.

Update if there is any available before Saving it.
create a new CATDrawing file and name it as "Back Door Wiring Harness Drawing". Select the "front view" command and then select required plane in the Flattened Harness assmebly to pull the flattned view into the drawing sheet.
Go to properties and enable the "3D wire frame" option and "3D colors" click ok and save the drawing file.

In the end, ensure that context assembly is removed and only the Harness assembly (Containing Geometrical Bundle ) is delivered.