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

AIM :

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.

1. Deutsch DT06 – 08SA ( https://www.te.com/usa-en/product-DT06-08SA.html)
2. Tyco 174357-2 (https://www.te.com/usa-en/product-2-174357-2.html?source=header-match)
3. Tyco 85229-1 – (https://www.te.com/usa-en/product-85229-1.html?q=85229&source=header)

Introduction

What is a Wire Harness?

A wire harness, often referred to as a cable harness or wiring assembly, is a systematic and integrated arrangement of cables within an insulated material. The purpose of the assembly is to transmit a signal or electrical power. Cables are bound together with straps, cable ties, cable lacing, sleeves, electrical tape, conduit, or a combination thereof. The wire harness simplifies the connection to larger components by integrating the wiring into a single unit for “drop-in” installation.

Cable wire assembly

Wire Harnesses vs. Cable Assemblies

Wire harnesses are often confused with cable assemblies however, the two are quite different. The main difference is that a cable assembly normally has only two ends, whereas a wire harness contains multiple breakouts (ends) that run in many different directions with multiple terminations on each breakout.

Wire assemblies are most commonly used in the transportation industry, including automobiles, buses, trucks, and planes. Construction machinery, industrial equipment, electronics and white goods (household appliances) will also be constructed using wire harnesses.

Wire Harness Assembly Benefits

Decreased installation time: Many vehicles require miles of wiring in order to operate. A wire harness assembly process greatly simplifies the manufacturing of these vehicles by integrating all the wires and cables needed into a single apparatus. The installation then becomes a simple matter of “dropping in” the harness, rather than running all of the wires individually.

Security and safety: When wires and cables are bound within a single harness, the individual components are more secure against the adverse effects of vibrations, abrasions, and moisture. Space is optimized and the risk of an electrical short is reduced because the wires have been constructed into a non-flexing bundle. The risk of electrical fire is also reduced when the wires are bound within a flame-retardant sleeve.

Wire Harness Design and Pre-Production

A wire harness process is designed based on the geometric and electrical requirements of the equipment it is to be installed in. Once the initial design is established, a schematic is used to create the manufacturing paperwork and the assembly board for the harness. The assembly board, also called a pin board, is a full-size diagram of the harness that shows all of the components and their locations. It also serves as the workbench for the harness.

The steps involved.

Download the zip files from the given links and unzip them to get the actual drawings.

import the part drawings one by one.

Tyco 174357-2:

Identify points in the center portion for bundle, connector, and cavity engagement.

define axes for connector connection and mounting clip

Define the connector connection points and bundle connection points and cavity points.

define the whole component as a connector.

Tyco 85229-1 :

Create midpoint

create a cavity connection point

create cavity connection axis system and orientation should be the same as in connector

Switch to Electric part design and define the part as Mounting Equipment

Define cavity connection point

Deutsch DT06:

Create a midpoint on the contact face which will be normal to wire bundle insertion.

Create another midpoint on the face where the connector should match and create an axes system with respect to this point.

Defie the component as connector and create connector connection point and bundle entry points based on the above mid points . Define the part as connector in CATIA, give no. of termination as 8 because we have 8 entry points for wire.