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

WIRING HARNESS DESIGN

Objective

The objective of this project is to explore various connector and connector clip models and transform them into electrical components using the CATIA V5 tool. This involves defining essential properties and comprehending the wiring harness design process by creating necessary provisions for assembly in the workbench.

Introduction

Wiring Harness

A wiring harness, also known as a cable harness or wiring assembly, is a methodical arrangement of cables within an insulated material. Its purpose is to transmit signals or electrical power. Cables are bundled together using straps, ties, lacing, sleeves, tape, conduit, or a combination thereof. This integrated wiring simplifies connections to larger components by incorporating the wiring into a single unit for effortless installation. The harness comprises various connectors such as terminals and wires running throughout the vehicle, transmitting essential information.

The wire harness design process is tailored to the geometric and electrical requirements of the equipment it will be installed in. After establishing the initial design, a schematic is created to generate manufacturing documentation and the assembly board for the harness. The assembly board, also known as a pin board, provides a full-size diagram of the harness, detailing all components and their respective locations. It serves as the workbench for the harness assembly.

Connectors

Connectors are coupling devices that join electrical terminations to establish electrical circuits. They facilitate contact between wires, cables, printed circuit boards, and electronic components, ensuring reliable transmission of data, power, and signals even in harsh environments. Connectors are designed to endure tough conditions, offer retention, EMI shielding, and reduce application size and power usage while enhancing performance.

Steps Followed

Understand the connector model and its connection to the compatible mating part and cavity clipping arrangement.

Customize wiring harness settings and create a standard catalog for the electrical part connector using the CATIA V5 tool. Define the connector type and properties.

Download the neutral data file (STEP file/IGS file) of the connector and cavity clip from the provided source (TE Connectivity website) and import it into the CATIA part file.

Position the connector axis and center points for both bundle connection and connector connection points, ensuring proper alignment and orientation.

For clip-mounted connectors, identify the clipping arrangement, define the center point, and establish the axis system based on the mating face with the cavity clip.

Repeat the above steps for all connector compatible parts and cavity clips, saving them as CATIA part files in the designated folder.

In the electrical part design, add the connector part files to the catalog, specifying the connectors' family.

Define the connector using the 'Define Connector' command, specifying the appropriate number of terminal points.

Define the bundle connection points and connector connection points for the connector compatible parts, ensuring correct representation, contact faces, and orientation directions.

Define the cavity clip arrangement by specifying the representation, contact face, coincidence axis, and orientation direction.

Assemble the electrical part models in the electrical assembly design workbench, adjusting their positions using the 'Connect Electrical Devices' tool. Note that certain connector parts may not be compatible, requiring assembly of 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

In conclusion, the transformation of connectors and cavity clips from the standard CAD part model to the electrical part model has been successfully accomplished using the specialized features of the Electrical Part Design workbench in CATIA V5. By precisely defining the bundle side, connector side, cavity, connector clips, and compatible mating parts within the electrical part model, the necessary elements have been converted and prepared for integration.

This comprehensive process not only involved the conversion but also included the creation of essential provisions to facilitate their seamless connection within the assembly. Understanding the intricacies of the wiring harness assembly process was fundamental to this endeavor.

By leveraging CATIA V5's Electrical Part Design capabilities, the project has achieved its objectives, ensuring the efficient integration of connectors and cavity clips into the wiring harness assembly. This successful transformation marks a significant milestone in enhancing the design and assembly processes, contributing to the overall efficiency and functionality of the electrical systems they are implemented in.