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

WIRING HARNESS DESIGN IN CATIA V5

Aim:

Electrically defined the given connecters and connecter clip with the help of geometry and assemble by the electrical wiring harness workbench.

INTRODUCTION:

Wiring harness is the combination of electrical and mechanical CAD to connect all the electrical parts in the automotive at the optimum level.

Facilitate customization for specific application needs

Improve the safety of the equipment
Optimize space by grouping different wires together
Cost-effective solution for organizing multiple cables
Best suited for indoor applications
Convenient for modifying constituent cables
Important Guidelines for Cable and Wire Harness Assembly

• 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

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.

DESIGN OF WIRING HARNESS IN CATIA V5

To design the wiring harness in CATIA V5, the interface and some settings have to be changed in the design modeler.

The electrical part design, electrical harness assembly, electrical harness installation, electrical harness flattening, and electrical assembly design have to be customized to the workbench for easy access.

1) Electrical part design: The mechanical part is converted into an electrical part by manipulating the electrical properties into it.

2) Electrical Harness Installation: Route the harness.

3) Electrical Harness Flattening: Finalizing the routing

CUSTOMIZED SETTINGS FOR ELECTRICAL ENVIRONMENT

An electrical catalog has to be made to save the electrical parts into it and use it whenever required.

1)Infrastructure settings: In the product structure option enable cache management.

2) Equipment and system: In Electrical mapping select the connector catalog which is created as an electrical catalog.

3) Electrical Harness installation

Vehicle electrical Distribution System(EDS) Introduction.
EDS have 4 parts
1. E&E architecture
2. Logic Schematics
3. Schematic Development
4. Wiring Harness Routing and Packaging

WIRING HARNESS ASSEMBLY DESIGN:

• First we download the files from the above given link in the challenge.
• Then we open the 'Part Design' workbench and save the file.
• Then we use point "In bewteen" command to create a point for the connection points
• After that we create axis system from the point and define the orientation.
• Then we switch to the 'Electrical Part Design' Workbench.
• After that we define the type of equipment.
• At last we define the necessary points such as Cavity connection Point and Bundle Connection point
• Then we save the component.
• 1. DT06 – 08SA
• Connector connection point

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

• Craete Axis System with respect to the point which we have created and defining the axis direction as shown below,
• 

• Switch to 'Electric Part Design'

• Define the part as connector in catia, give no. of termination as 8 because we have 8 entry points for wire.
• 
• 
• Define Bundle connection point
• 
• CAD TREE-
• 

Define connector connection point

• 

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

• 
• Defining axis system for connection Clip
• 
• Define electrical device-
• 
• Defining Bundle Connection Point
• 

• Defining Connector Connection Point

• 
• 
• CAD TREE-
• 

3. Tyco 85229-1 :

For this part we have created the point and axis system where the clip will be attached to Tyco 174357-2. Also we defined the part as a Cavity so the software can recognise when we assemble the two parts.

• 
• 
• 
• CAD TREE-
• 
• ASSEMBLY -
• 
• 
• 
• ASSEMBLY CAD TREE-
• 
• CATALOGUE DOCUMENT:
• ALL CAD FILES ARE ATTACHED-
• THANKYOU