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

Aim

To define the following connectors & Connector clip cad data from given link as Electrical Connector using Electrical Part design Workbench with 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)

INDRODUCTION

• Wiring Harness

A wiring harness, also known as a cable harness or wiring loom, is a collection of wires, connectors, and other electrical components assembled together to form a complete electrical system. It is typically used to transmit electrical signals and power between different components in a vehicle or machinery.

Wiring harnesses are designed to provide a reliable and secure connection between various electrical components, while minimizing the risk of electrical interference or signal loss. They can vary in size and complexity depending on the application, ranging from simple assemblies with only a few wires to complex harnesses with hundreds or even thousands of wires.

Wiring harnesses can be custom-designed for specific applications, or they can be pre-manufactured for use in a wide range of vehicles and machinery. They are typically made up of several individual wires that are bundled together, either by wrapping them in a protective sheath or by using clips or other fasteners to hold them in place.

Overall, wiring harnesses play a critical role in modern electrical systems, helping to ensure the safe and efficient operation of a wide range of equipment and devices.

• Vehicle Electrical Distribution System (EDS)

A vehicle electrical distribution system is a complex network of wires, connectors, and electrical components that work together to provide power and control signals to various systems and components in a vehicle. The electrical distribution system is responsible for delivering power from the battery to various subsystems such as the engine, transmission, lights, entertainment system, and other electronic devices.

The key components of a vehicle electrical distribution system include the battery, alternator, starter motor, and various relays and fuses. The battery serves as the primary power source for the system, while the alternator is responsible for recharging the battery and providing power to the electrical system while the engine is running. The starter motor is responsible for starting the engine, while the relays and fuses help to protect the system from damage due to electrical faults and overload conditions.

• Wiring Harness Design Process

• Wiring harness Assembly Structure – Connector Definition

Following Parameters are required to define for any Connector:

• Geometry Parameters – Points & Co-ordinate system (Axis)
• Connector Connection Points – This point is used for the connection of one connector to another connector.
• Harness Bundle Entry Point – This point defines where the harness bundle segment point will end when routed to the electric connector.
• Cavity Connection Point (Optional) – This point is used to define the connection of a connector to a connector clip. This only applies to connectors which have the mounting feature for a connector clip.

• Comments used in Electrical part work bench:

• Define connecters - This option is used to define the connecter with buddle entry points. After this process CATIA will take the part as connecter.
• Define mounding equipment - This option is used to define as mounding equipment. After this process it take as mounding equipment.
• Define connecter connection point - This option is used to define the connecter connection point with the help representation, contact, coincident and orientation which are given by point, surface and axis system.
• Define bundle connection point - This option is used to define the bundle entry point of connecter with the help representation, contact, coincident and orientation which are given by point, surface and axis system.
• Define cavity connection point - This option is used to define the cavity connection point of connecter with the help representation, contact, coincident and orientation which are given by point, surface and axis system.
• Define cavity - This option is used to define the cavity connection point of mounding equipment with the help representation, contact, coincident and orientation which are given by point, surface and axis system.

• Comments used in Electrical assembly:

• Connect electrical device - This option is used to connect the two electrical devices. When the both parts are defined electrically it automatically assembles with help of point, axis, and face.
• Disconnect electrical device - This option is used to disconnect the two electrical devices from connected devices.

PROCEDURE

• Creation of catalogue.

• Deutsch DT06 – 08SA

• Open Deutsch DT06 – 08SA in ‘Part Design’ Workbench.
• Creation of connector connection point and Connector Connection Axis.

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

Create Axis System with respect to the point which we have created and defining the axis direction.

1. The Y-Axis should be oriented towards the connector's front face.
2. The X-Axis should be oriented towards the clip's locking mechanism.
3. The Z-axis should be pointing across the connector from left to right.

• Creation of Bundle Connection Point.

• Switch to 'Electric Part Design' Workbench.
• Define part as a connector.

Define the part as a connector by specifying that there are 8 terminations as there are 8 wire entry points.

• Define Bundle connection point.

• Define connector connection point.

• Tyco 174357-2

• Open Tyco 174357-2 in ‘Part Design Workbench.
• Creation of connector connection point and Connector Connection Axis.

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

Create an axis system referencing the newly generated point and specifying the axis direction.

• Creation of Cavity Connection Point and Cavity Connection Axis.

• Creation of Bundle Connection Point.

• Switch to 'Electric Part Design'.
• Define part as a connector.

Define the part as a connector by specifying that there are 3 terminations as there are 3 wire entry points.

• Define Bundle connection point.

• Define connector connection point.

• Define cavity connection point.

• Tyco 85229-1

• Creation of cavity connection point.

• Creation of cavity connection axis system.

The orientation of cavity connection axis should be same as that of connector.

• Define the part as a Mounting Equipment.

• Cavity Definition.

• FINAL ELECTRICAL ASSEMBLY DESIGN.

Conclusion

Thus the given Connecters and Connector clips are successfully defined as electrically using Electrical Part design Workbench in CATIA V5 with all the necessary properties.