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

WIRING HARNESS DESIGN

Aim

The aim of the project is to study and understand the different models of the connector and connector clips and convert them into electrical parts using CATIA V5 tool. Then define all necessary properties and understand the wiring harness design process by creating the required provisions for connecting them in the assembly workbench.

Introduction

Wiring 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 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. A wiring harness consists of different sets of connectors like terminals and wires which run through the entire vehicle and transmit information.

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.

Connectors

A connector is a coupling device that joins electrical terminations to create an electrical circuit. Connectors enable contact between wires, cables, printed circuit boards, and electronic components that are engineered to reliably transmit data, power, and signal in the harshest environments. It offers to withstand harsh conditions, retention, EMI shielding and reduces application size and power usage while enabling increased performance.

Steps followed

• Read and understand the model of the connector and how it is connected to the mating compatible part and cavity clipping arrangement.
• Customized settings for the wiring harness are done and create a standard catalog for the electrical part file connector by using the new catalog document and add family option available in the popup screen by renaming it as desired name and type as standard.
• Now create a catalog under equipment & system options by using the new catalog document and add family option available in the popup screen by renaming it as desired name (connector) and type as electrical.
• Download the neutral data file (step file / igs file) of the connector and cavity clip from the given source (TE connectivity website) and open it in the CATIA part file.
• Open one of the connector compatible part (don’t have the cavity clip mounting arrangement) and locate the center point of the connector on either side (bundle connection point & connector connection point) by selecting the two points on the outermost edge of each contacting face. Position the axis of the connector connection point with respect to the center point by placing the Y axis towards connecting point (mating point) direction and the X axis pointing towards the side of the locking mechanism.
• For the clip mounted connector compatible part first we need to identify the type of clipping arrangement used for this connector and understand the mating face for them. Place the axis system by defining the center point on one edge of the mating face with cavity clip and the axis direction should be the same as the axis direction given for the connector connection point.
• Follow the same steps for all the connector compatible parts as well as cavity clips and save all as CATIA part files in the same folder.
• Now switch to the electrical part design and add the connector part file into the catalog by opening the newly created catalog in store device option and selecting the family as connectors.
• Define the cad part model as a connector by using the define connector command available in the electrical part design workbench by giving the appropriate number of terminal points.
• By using the define bundle connection point command available in the electrical part design workbench and by selecting the face of bundle entry side and the created bundle center point define the bundle connection point of connector compatible part.
• The next step is to define the connector connection point by giving the representation as the connection point, selecting the face of contact, coincidence direction as Y axis and orientation direction as X axis.
• Follow the same step for both the mating compatible parts of the connector.
• For the compatible part having cavity clip arrangement we have to define the representation, contact face, coincidence axis and orientation direction by selecting the representation as cavity clip point, the face of contact of the cavity clip, coincidence direction as Y axis and orientation direction as X axis.
• Connector clip is then opened in the cad part file and create the center point and axis system with respect to the compatible part having cavity clip arrangement and the locking mechanism.
• The cavity clip part model is first defined as mounting equipment by using the define mounting equipment tool and by selecting the define cavity tool it will have defined as a cavity.
• If all these electrical part models need to be assembled together we have to open them in the electrical assembly design workbench by copying and pasting them or by adding the existing component command available in the insert toolbar. Then by using connect electrical devices tool we can join them together by adjusting them to the appropriate location. Here the given connector parts are not compatible with each other so we have assembled the cavity clip and one part of the compatible connector.

1) Model-1 connector (Deutsch DT06 – 08SA)

Input cad received

Open one of the connector compatible part (don’t have the cavity clip mounting arrangement) and locate the center point of the connector on either side (bundle connection point & connector connection point) by selecting the two points on the outermost edge of each contacting face. Position the axis of the connector connection point with respect to the center point by placing the Y axis towards connecting point (mating point) direction and the X axis pointing towards the side of the locking mechanism.

• Now switch to the electrical part design and add the connector part file into the catalog by opening the newly created catalog in store device option and selecting the family as connectors.
• Define the cad part model as a connector by using the define connector command available in the electrical part design workbench by giving the appropriate number of terminal points.

By using the define bundle connection point command available in the electrical part design workbench and by selecting the face of bundle entry side and the created bundle center point define the bundle connection point of connector compatible part.

The next step is to define the connector connection point by giving the representation as the connection point, selecting the face of contact, coincidence direction as Y axis and orientation direction as X axis.

2) Model-2 Connector (Tyco 174357-2)

Input cad received

For the clip mounted connector compatible part first we need to identify the type of clipping arrangement used for this connector and understand the mating face for them. Place the axis system by defining the center point on one edge of the mating face with cavity clip and the axis direction should be the same as the axis direction given for the connector connection point.

• Now switch to the electrical part design and add the connector part file into the catalog by opening the newly created catalog in store device option and selecting the family as connectors.
• Define the cad part model as a connector by using the define connector command available in the electrical part design workbench by giving the appropriate number of terminal points.

By using the define bundle connection point command available in the electrical part design workbench and by selecting the face of bundle entry side and the created bundle center point define the bundle connection point of connector compatible part.

The next step is to define the connector connection point by giving the representation as the connection point, selecting the face of contact, coincidence direction as Y axis and orientation direction as X axis.

For the compatible part having cavity clip arrangement we have to define the cavity connection point by defining the representation, contact face, coincidence axis and orientation direction by selecting the representation as cavity clip point, the face of contact of the cavity clip, coincidence direction as Y axis and orientation direction as X axis.

3) Model-3 connector clip (Tyco 85229-1 )

Input cad received

Connector clip is then opened in the cad part file and creates the center point and axis system with respect to the compatible part having cavity clip arrangement and the locking mechanism.

The cavity clip part model is first defined as mounting equipment by using the define mounting equipment tool and by selecting the define cavity tool it will have defined as a cavity.

Final electrical cavity clip

Electrical assembly workbench

Open the electrical assembly design workbench by copying and pasting them or by adding the existing component command available in the insert toolbar.

By using connect electrical devices tool we can join them together by adjusting them to the appropriate location. Here the given connector parts are not compatible with each other so we have assembled the cavity clip and one part of the compatible connector.

Conclusion

The connectors, and cavity clips in the normal cad part model are converted into the electrical part model by defining the bundle side, connector side, cavity, connector clips and compatible mating parts using the electrical part model workbench in CATIA V5 then create the required provisions for connecting them in the assembly and understanding the process of wiring harness assembly.