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

Objective : 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

The automotive wiring harness is referred to as the central nervous system in the vehicle. It mainly consists of an electrical harness and the mechanical harness in the design. The current project is focused on the mechanical wiring harness and its rules and procedure to be followed while routing in the virtual condition. CATIA V5 electrical workbench is used as the CAD tool for routing the wires in the engine and tailgate components.

Basics of the electrical distribution system and wiring harness

• Electrical Distribution System (EDS): It deals with physical (location of electronic components placed in the vehicle, front end to back end) and logical (different Electrical Control Units) architecture, schematic development, power distribution (set with fuses to check wiring harness is safe in various failure modes), wiring harness design and wiring harness component design of given electrical system.
• E & E Architecture: It is a high-level logical connectivity diagram representing the number of systems, sub-systems, and logical connections between them. It is also extended to show the CAN (control area network) network between different electronic controllers.
• Logical schematics: It is detailed design of E&E architecture which is extended to show the logical connectivity between different components and controls of different systems and sub-systems.
• Electrical schematics: It is detailed design of logical schematics, which describe the pin-to-pin connectivity, properties, fusion distribution, grounding distribution, wire properties (wire type, colour, gauge), interconnects, circuit properties (circuit numbers, connector designation numbers, control device number), specification of component (rating od diode, resistors) etc., This is the end design of electrical core design of system and used as primary input for harness development.
• Wiring harness topology: It is strategy to divide the harness between different pieces to achieve the best manufacturability, serviceability and cost-effective design.

Ex: engine harness, door harness, tail gate harness.

Note: Wiring harness cannot be repaired. It is advised to replace the damaged wiring harness parts.

• Wiring harness routing: It is the desired path of wiring harness into given vehicle environment by applying set of design rules and industry best practices.
• Wiring harness packaging: deals with the 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.
• Virtual environment: 3D representation of vehicle components.

Benefits: 1) Huge cost saving, 2) Fuse failure avoiding, 3) Easy to predict i.e., warning in harness

Logical Architecture, Electrical Schematics and Physical Architecture are designed by the electrical department whereas harness Routing and packaging is developed by mechanical department. Upon integration of electrical and mechanical departments final harness drawing is designed.

Wiring Harness Design Process

Wiring harness design process.

Wiring harness design process.

Connector definition and the detailed process.

Geometry Parameters – Points and 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 electrical 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.

CONNECTOR DEFINATIONS IN CATIA V5

1. Deutsch DT06 – 08SA

Connector connection point:

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

Connector axis system definition.

Once the bundle and connector entry points and axis system are created in part design workbench as shown in switch to electrical part design workbench. In electrical part design workbench click on Define Connector option and click the connector and enter the type, name and number of terminations.

Connector Definition

Change the termination names as 1,2,3,4,6,7,8 as given in the part.

Termination name changed to 1,2,3,4,5,6,7,8.

Now define the connector connection point definition by clicking Define connector Connection and give the details

Bundle definition.

Now give the bundle connection point definition by clicking Define Bundle Connection and give the details as given.

Add connector to catalogue. Click on store device command and select the connector catalogue that is already created and give type as connector and click on ok.

2.Tyco 174357-2 

• Create midpoint
• create Connector connection point
• create Connector connection axis system
• create cavity connection point
• create cavity connection axis system
• Switch to Electric part design and define part as connector
• Define Connector connection point and cavity connection point

3. Tyco 85229-1 

• Create midpoint
• create cavity connection point
• create cavity connection axis system and orientation should be same as in connector
• Switch to Electric part design and define part as Mounting Equipment
• Define cavity connection point

Elctric Assembly Design

• Import Connector and cavity / mounting clip.
• Select Defing Eelectric connection 
• select cavity and then connector.

Conclusion :

1. Downloaded connectors & Connector clip cad data from given link & defined it as Electrical Connector using Electrical Part design Workbench.

2. Created a catalogue for the components.