Wiring harness design in CATIA V5 - 3D modeling Week 2 Challenge

Title: Defining Connectors and Clips using CATIA V5

Objective : Downloading the 3D CAD files form the te.com website and then defining the parts electrically and further creating a catalogue for the components.

WIRING HARNESS DESIGN IN CATIA V5

INTRODUCTION

Wiring harness is the combination of electrical and mechanical CAD to connect all the electrical parts in the automotive at the optimum level.

BASICS OF ELECTRICAL DISTRIBUTION SYSTEM (EDS) AND WIRING HARNESS

1) Electrical Distribution System: It runs from front end to rear end of the vehicle. It involves physical and logical architecture schematic development, power distribution, wiring harness design, wiring harness component design of given electrical system. It ensures the physical location of all electrical components placed in the vehicle. It provides the logical connectivity between electrical components. It has electrical controller unit for different sections like Airbag ECU, ABS ECU, Engine (ECU).

2) E&E Architecture: It is the high-level logical connectivity diagram. It represents all the systems, sub-systems and logical connections between them. It shows the Control Area Network (CAN) between different electronic components.

3) Logical schematics: Detailed design of E&E architecture. It shows the logical connectivity between different components and controls of given systema and subsystem. It does not define any other parameter except electrical connectivity.

4) Electrical schematics: Detailed design of logical schematics, pin to pin connectivity, properties, fusing distribution, grounding distribution, interconnects, wire properties (wire gauge, color, type), circuit properties (circuit number, connector designation number, control device number), specification of components, end results of electrical core design of system and primary input for harness design.

5) Wiring harness topology: Strategy to split the harness between different pieces to achieve the best manufacturability, serviceability and cost-effective design.

6) Wiring harness routing: It provides the desired path of wiring harness into given vehicle environment by applying set of design rules and industry best practices.

7) Wiring harness packaging: Fixing/mounting strategy of wiring harness routing to ensure the safe, reliable and durability of wiring harness by applying set of design rules and industry best practices.

WIRING HARNESS ASSEMBLY

The term Wiring Harness refers to the assembly of

1) Wires: Various bundled wires together. Each individual wire is responsible for carrying the electrical signals and energy. Wires are made up of Cu conductors insulated with PVC insulation.

2) Connectors: These are electro-mechanical device used to join electrical termination. Connectors create an electrical circuit. These are plastic molded housing with locking and retention feature.

3) Terminals: A device used to terminate a conductor that is to be affixed to post, stud, chassis, another tongue etc., to establish electrical connection. These are metal conductors with plating constructed in specific shape.;

4) Protection devices: Corrugated flexible tube.

5) Insulation: adhesive and non-adhesive tapes and sleeves. Polymer or cotton/polymer (very effective in high-temperature zone).

6) Clips & Clamps: Plastic molded parts with mounting /snapping features.

7) Fuse and relay box: Plastic molded parts used to package fuses and relays in systematic manner.

8) Retention device: Plastic molded parts to mount connector and other harness components. Connector backshells.

9) Guiding channels: Plastic molded parts or metal parts designed to guide harness bundle in given geometric area to secure and protect the harness.

10) Electronic components: Diodes, terminating resistors, flasher, Timer circuits are some parts of harness supply.

DESIGN OF WIRING HARNESS IN CATIA V5

To design the wiring harness in CATIA V5, the interface and some settings have to be changed in the design modeler.

The electrical part design, electrical harness assembly, electrical harness installation, electrical harness flattening, and electrical assembly design have to be customized to the workbench for easy access.

1) Electrical part design: The mechanical part is converted into an electrical part by manipulating the electrical properties into it.

2) Electrical Harness Installation: Route the harness.

3) Electrical Harness Flattening: Finalizing the routing

A connector is a device(or more precisely, a mating pair of devices, often a plug and a socket) for connecting together two or more wires, cables, or hoses, allowing electricity or fluid to flow but also allowing easy disconnection and reconnection when necessary.

Mounting Clips are used for supporting conduits. These clips are made of High Quality Impact Resistant Polyamide. The mounting clips are stackable and are fixed with the help of screws on to the panel or equipment surface.

Specifications:

Connectors:- 1. Deutsch DT06 – 08SA

2. Tyco 174357-2

Mounting Clip:- 1. Tyco 85229-1

Design Methodology:

A connector is a device[or more precisely,a mating pair of devices,often a plug and a socket]for connecting to gether two or more wires,cables,or hoses,allowing electricity or fluid to flow but also allowing easy disconnection and reconnection when necess ary.

mounting clips are used for supporting conduits.These clips are made of high quality impact resistant resistan polyamide.The mounting clips are stackable and are fixed with the help of screws on the panel or equipment surface.

PROCEDURE

DEUTSCH

• First open the 3D CAD data in CATIA and then convert the file formate to.CAT Part.
• Then define the connector gemetrically in the CATIA Part design workbench.To do that we have to first assign a mid-point to the bundle connection side face of the connector and the we also have to assign a mid-point to connector connection side of the connector along with that we also have to assign an axis system on the mid-point of the connector connector connection side face.This will allow is to fully define our connector geometrically.
• After that start the electrical part design workbench in CATIA to define the coonector electrically.
• First we select the define connector option from the toolbars and then we select the connector body and also assign the number of terminals to the connector which in the case are 8 terminals.
• Then we select the define bundle connection point option from the toolbar and then we select the connector body bundle contact face for reperntation mid-point for point and agine bundle contact face for intail condition and then click on ok.
• Lastly we select the define connector connection point option from the toolbars and then we selection the connector body mid-point for toolbars and then we select the connector body mid-point for represenation contact face for contact,Y-axis for coincidence and X-axis for oriention and then click on ok.This will fully define our connector electrically.

Fig1: Connector(Deutsch DT06 – 08SA) Views

CONNECTOR

• First open the 3D CAD data in CATIA and then convert the file formate to.CAT Part.
• Then define the connector gemetrically in the CATIA Part design workbench.To do that we have to first assign a mid-point to the bundle connection side face of the connector and the we also have to assign a mid-point to connector connection side of the connector along with that we also have to assign an axis system on the mid-point of the connector connector connection side face.This will allow is to fully define our connector geometrically.
• Also we have to creat a mating reference at the bottom side of the connector so that we can mount a clip on to the connectors.To do that we can just creat mid-point and an axis system will have contact with the clip .this will allow us to fully define our connector geometrically.
• First we select the define connector option from the toolbars and then we select the connector body and also assign the number of terminals to the connector which in the case are 8 terminals.
• First we select the define connector option from the toolbars and then we select the connector body and also assign the number of terminals to the connector which in this case are 3 terminals.
• Then we select the define bundle connection point option from the toolbars and then we select the connector body, bundle contact face for representation, mid-point for point, and again bundle contact face for initial condition and then click on ok.
• Then we select the define connector connection point option from the toolbars and then we select the connector body mid-point for representation,contact face forcontact Y-axis for coincidence and X-axis for orientation and then click on ok.
• Then we select the define cavity connection point option from the toolbars and then we select the connector body bottom side mid-point as repersentation mating face for contact Y-axis for coincidence and X-axis for orientation and then click on ok.This will fully define our connector electrically.

Fig2: Connector(Tyco 174357-2) Views

MOUNTING CLIP

• First open the 3D CAD data in CATIA and then convert the file formate to.CAT Part.
• Then define the clip geometrically in the CATIA part design workbench.To do that we can just creat a mid-point and an axis system with that mid-point as reference on the face which will have contact with the connector.This will allow us to fully define our clip geometrically.
• After that start the electrical part design workbench in CATIA to define the clip electrically.
• First we select the define cavity option from the toolbar and then select the clip body mid-point for representation,contact face for contact,Y-axis for concidence and X-axis for orientation and then click on ok.This fully define our connector electrically.

Fig3: Mounting Clip(Tyco 85229-1) Views

TREE STRUCTURE :