Wiring harness design in CATIA V5 - 3D modeling Week 2 Challenge
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Wiring harness design in CATIA V5 - 3D modelling Week 2 Challenge
v Objective: -
1. The main objective of this project is to downloading the 3D CAD files form the te.com website and then defining the parts electrically.
2. Further creating a catalogue for the components.
v Introduction: -
A connector is a device; or precisely, a mating pair of devices, often a plug and a socket; for connecting together two or more wires, cables, or hoses, allowing electricity or fluid to flow. Also ensures the easy disconnection and reconnection whenever necessary.
Mounting Clips are used for supporting conduits. These clips are made of High Quality Impact Resistant Polyamide. The mounting clips are stackable and are fixed with the help of screws on to the panel or equipment surface.
v Specifications: -
As given below following parts to be used to complete this assignment.
A. Connectors:-
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)
B. Mounting Clip:-
Tyco 85229-1: (https://www.te.com/usa-en/product-85229-1.html?q=85229&source=header)
v Introduction To Wiring Harness: -
Definition:
Wiring harness is the combination of electrical and mechanical CAD to connect all the electrical parts in the automotive at the optimum level.
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, and 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 system 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 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.
7) 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.
1. Connector 1
A. First open the 3D CAD data in CATIA and then convert the file format(.igs or .stp) to .CATPart.
B. Define the connector geometrically in the CATIA Part Design Workbench. For thisI have to first assign a mid-point to the bundle connection side face of the connector and then we also have to assign a mid-point to connector connection side of the connector, along with that we also have to assign an axis system on the mid-point of the connector connection side face. This will allow us to fully define our connector geometrically.
C. Start the Electrical Part Design Workbench in CATIA to define the connector electrically.
D. First we select the define connector option from the toolbars and then we select the connector body and also assign the number of terminals to the connector which in this case are 8 terminals.
E. Then we select the define bundle connection point option from the toolbars and then we select the connector body, bundle contact face for representation, mid-point for point, and again bundle contact face for initial condition and then click on ok.
F. Lastly we select the define connector connection point option from the toolbars and then we select the connector body, mid-point for representation, contact face for contact, Y-axis for coincidence and X- axis for orientation and then click on ok. This will fully define our connector electrically.
G. Save the file.
Fig A: Connector (Deutsch DT06 – 08SA) Views
2. Connector 2:
Tyco 174357-2 & Tyco 85229-1
A. First open the 3D CAD data in CATIA and then convert the file format (.igs or .stp) to .CATPart.
B. Define the connector geometrically in the CATIA Part Design Workbench. For this we have to first assign a mid-point to the bundle connection side face of the connector and then we also have to assign a mid-point to connector connection side of the connector, along with that we also have to assign an axis system on the mid-point of the connector connection side face. This will allow us to fully define our connector geometrically.
C. Start the Electrical Part Design Workbench in CATIA to define the connector electrically.
D. First we select the define connector option from the toolbars and then we select the connector body and also assign the number of terminals to the connector which in this case are 8 terminals.
E. Then we select the define bundle connection point option from the toolbars and then we select the connector body, bundle contact face for representation, mid-point for point, and again bundle contact face for initial condition and then click on ok.
F. Lastly we select the define connector connection point option from the toolbars and then we select the connector body, mid-point for representation, contact face for contact, Y-axis for coincidence and X- axis for orientation and then click on ok. This will fully define our connector electrically.
G. Save the file.
Fig B: Connector (Tyco 174357-2) Views
For Mounting Clip:
A. First open the 3D CAD data in CATIA and then convert the file format (.igs or .stp) to .CATPart.
B. Then define the clip geometrically in the CATIAPart Design Workbench. To do that we can just create a mid-point and an axis system with that mid-point as reference on the face which will have contact with the connector. This will allow us to fully define our clip geometrically.
C. After that start the Electrical Part Design Workbench in CATIA to define the clip electrically.
D. First we select define mounting equipment option from the toolbars and then we select the clip.
E. Then we select the define cavity option from the toolbars and then select the clip body, mid-point for representation, contact face for contact, Y-axis for coincidence and X- axis for orientation and then click on ok. This will complete electrically define our connector.
F. Save the file.
Fig C: Mounting Clip (Tyco 85229-1) Views
For Connector and clip assembly:
A. Start the Assembly Design Workbench in Catia. Copy the connector and clip parts and paste in the assembly tree. Rotate both the models in order to give them proper orientation so that they can come in contact properly.
B. Start the Electrical Assembly Design Workbench in Catia. Select “Connect electrical devices” option from the toolbars and then select the connector and clip to mount then together.
C. Save the file
Fig4: Connector (Tyco 174357-2) and Clip (Tyco 85229-1)