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

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

Aim:-

Q1. Download the following connectors & Connector clip cad data from the given link & define it as Electrical Connector using the Electrical Part Design Workbench. Define all the necessary properties of Connectors & clips.

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)

Prepare a proper report with the necessary images in the answer box provided

Solution:-

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.

Steps to define 3D Connectors as Electrical Connectors using the Electrical Part Design Workbench -

i. Create/Download connector 3D

ii. Mechanical Part Design

• Defining geometrical parameters by point and axis system (point for bundle/wire entry side, point and axis system for mating side).

iii. Electrical Part Design

• Define part as a connector
• Define bundle connection point (bundle/wire entry side)
• Define connector connection point (mating side)
• Define cavity connection point (optional, if connector needs mounting clip)

Defining bundle connection point at the bundle entry side where, representation is the face, point as the center point, and initial condition also as the face.

Defining connector connection point at the mating side of the connector where representation is the center point, contact is the face, coincidence is the Y axis, and, orientation is the X axis.