Project 2

Hello, 

The first step is to download the necessary connectors from the TE and open them in the CATIA. 

Electrifying the connectors

1) Swith the workbench to the Part design if it's present on another workbench.

2) Electrify the connector by using Define Connector.

3) For the bundle connection to the connector, choose the centre circle and create a centre point, Select the Define bundle connection point icon and select the Representation and Initial Point for the Connector back face, Bundle point for the centre point.

4) For defining the connector point, create a midpoint for the connector face and set up the axis in a way that Y-Axis points to the connection direction, X-Axis points to the locking system and Z-Axis to the remaining phase on either side. Select Define connector connection point then Select Representation for the midpoint, Contact for male and female connector connecting face, Coincidence for Y-axis and Orientation for X-Axis.

Electrifying the Support

1) Open in CATIA and Switch to Part Design, if it's in a different workbench

2) Create points on both sides using the Circle Centre or midpoint on the curve. 

3) Create panels on both sides taking Parallel through a point and taking the clip side for reference and centre point. Also, create another plane with a base of the clip for reference and offset as per the requirement.

4) Switch to Electrical Part Design and Select Define Support part. Select the right side point for the entry and its respective plane for plane bundle entry. Select the left plane on the left side of the clip and the base plane for the plane on the base side of the clip.

5) For the second entry for the clip, Select the left side point and its respective plane for bundle entry. The other two planes get automatically selected. Select OK. 

COT Tubes/PVC Tape

1) Select File -> New -> CatalogDocument -> Add Family -> Name: Slit COT -> Select Conduit from dropdown - > Select OK-> Save the Catalog -> Close

2) Select File -> New -> Part -> Enter Part Name: 15mm COT/ 20mm COT/ 35mm COT/ 10mm COT/ 5mm COT -> Select OK.

3) Select Define Protection Part and Click on either Part Number or Part Body on the tree.

4) Select Corrugated tube from the top down for Type.

5) Select Inner Diameter as 12 mm/17 mm/32 mm/ 7 mm/ 3mm, Thickness as 1.5 mm/1.5 mm/1.5 mm/1.5 mm/1 mm and Bend Radius as 1.5 times the Outer Diameter i.e 22.5mm/ 30mm/ 52.5mm/ 15mm/ 7.5mm -> Select OK -> Save

6) Select Store Device -> Select Slit COT Catalog saved path -> Select Slit COT from drop down -> Select OK

Routing the Harness

1) Create a New Product and Electrify it by using the Geometric Bundle in the Electrical Harness Assembly. Gather all the parts in the respective areas as per the Tailgate body with the use of the Compass and Manipulation tools.

2) Select the Multibranchable icon and in the Route, Definition select respective connectors/Clips to route the cable with a bend radius of more than 1.5. Make sure to get the length optimum between both the connectors.  

3) Add the bundle branch point to the required area on the trunk harness. 

4) Repeat the process until all the connectors are connected.

5) Switch to Electrical Harness Assembly, Select Protective covering and select the cable which needs to be added for covering and select the respective COT tube we have created before for application. 

6) Repeat the same process for the other branches as well. Now the Harness cable is routed and added for the protective coverings. 

Cable Continuity:

1) Once the harness bundle is done. Goto Edit -> Select Search -> Goto Advanced-> Select Workbench: Electrical, Type: Bundle Segment, Attribute: Fully Connected, Select: False -> OK

2) Click on Search. If there are no items found on the down section the bundle is fully connected and there are no linking problems. 

Harness Flattening and Drawing creation

1) Create a new Product and Switch to Harness Flattening workbench. 

3) Click on the Harness Flattening parameters option and select appropriate settings. Single line for Bundle Segment and Double line for Protective covering. The 3D projection for Device, Support and Nothing for Splice. Click OK.

4) Place the Harness and flattening product in Vertical windows. Select Extract and click on the harness product. Harness loads into the flattening product.

5) Select Flatten option and consider respective planes for the better flattening model.

6) Perform changes to the breakouts with the Rotate, Roll, Scaling etc tools for optimum design. 

7) After all the optimisation is done, Create a new Drawing file with respective drawing sheet sizes.

8) After opening the drawing sheet, Click on the Front view. Select the reference plane on the 3D drawing and the harness in will be shown on the drawing, Select the optimum view then click on the sheet. 2D Drawing will be updated on the sheet.

9) Right-click on the sheet and enter properties. Goto view section, select 3D Wireframe and click OK. Wiring bundles are shown on the drawing sheet now as per the below snap.

10) Corrugated tubes are represented with double lines on the drawing.

Thanks,

Uthej Reddy