Wiring harness design in CATIA V5 - 3D modeling Week 2 Challenge
WIRING HARNESS DESIGN IN CATIA V5
AIM
To Download following connectors & Connector clip cad data from given link & define it as Electrical Connector using Electrical Part design Workbench. Define all the necessary properties to Connectors & Clip.
- Deutsch DT06 – 08SA ( https://www.te.com/usa-en/product-DT06-08SA.html)
- Tyco 174357-2 (https://www.te.com/usa-en/product-2-174357-2.html?source=header-match)
- Tyco 85229-1 – (https://www.te.com/usa-en/product-85229-1.html?q=85229&source=header)
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.
PROCEDURE
Typical design flow of EDS System.
INTRODUCTION TO WIRE HARNESS
DEFINIG ELECTRIC PARAMETER FLOW CHART
Defining the connector
We need to define the connector by following the below steps.
- Download the connector data.
- Create required geometrical parameter.
- Define part as electrical connector.
- Define bundle connection point.
- Define connector connection point.
- Define cavity connection point.
Defining the mounting clip
- Download the clip 3d data.
- Create the geometry parameter.
- Define the part as mounting component.
- Define the part as cavity.
Defining the connector is described below
- Downloaded the cad data from the supplier's website and the images are shown below.
Then we have to put the axis system on the created points of the connectors with same orientation to ensure the correct assembly of the components.
- Defining the part as connector using the define connector command by selecting the command and selecting the component.
- Define bundle connection point and selecting the required input from the created geometries such as axis and points and face.
- Define the connector connection point and select the required geometry inputs for connector connection.
Creating required geometrical parameters for the connector side of DT06-08SA
Creating required geometrical parameters for the connector side of CENTERLINE 2-174357-2
Creating required geometricalm parameters for bundle side of DT06-08SA
Creating required geometricalm parameters for bundle side of CENTERLINE 2-174357-2
Then finally we have to define the cavity connection point, here the cavity connection point is only required when there is provision for the mounting clip is given.
After defining the connectors we need to define the clip also, defining the clip also has various step in it.For clip we need to define it as mounting component, and select the required input needed for defining it as a mounting component.
CLIP
CONCLUSION
The connector is successfully modeled in CATIA V5 and the same is added to the catalog for further references.