Project 2

Aim: Route the Wiring Harness on the given Car body and prepare to flatten the view drawing in CATIA V5

Objective: The objective of this project is to route the wiring harness and prepare to flatten the view drawing for the tailgate of the car. All types of packaging rules have to be considered while routing the harness and industry-based practices shall be demonstrated in harness design. All necessary details like clearance, clipping/clamping selection, harness fixing requirements, and harness continuity should be provided in order to design the wiring harness.

Assumptions:

 

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 the 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 solution

Description of Wiring routing:

• Now, we have to route the wiring harness for two tail lights and two number plate lights and connect them to the main electrical system of the car.
• For two tail lights and two number plate lights, we are using 2-pole connector.
• A car body also have an interconnection connector which will connect the wiring harness of tail gate of the car body to the main harness of the vehicle.
• We will use the 12-pole electrical connector with a mounting clip as an interconnection connector.
• The bend ratio for all the bundle segments is considered to be 1.4

The following steps are to be carried out for the wiring harness:

Step 1: Create context assembly for the wiring harness  

Step 2: Defined all the mechanical components as electrical 

  

 

Step 3: Fixing the position of all electrical components on the door Assembly 

and starts bundle routing of 1.4 band radius. provided protective covering tubes of 10mm and 5 mm.

Step 4: checking bundle connectivity found ok 

 

Step 4: Create flatten view of the wiring harness bundle

Step 5: Create a flatten view drawing for the wiring harness assembly