Wiring harness design in CATIA V5 - 3D modeling Week 2 Challenge
WIRING HARNESS DESIGN IN CATIA V5-3D MODELING WEEK 2 CHALLENGE
AIM :
DOWNLOAD FOLLOWING CONNECTOR & 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. DEUTSCH DT06-08SA...
- Deutsch DT06 – 08SA ( https://www.te.com/usa-en/product-DT06-08SA.html)
- Tyco 174357-2 (https://www.te.com/usa-en/product-2-174357-2.html?source=header-match)
- Tyco 85229-1 – (https://www.te.com/usa-en/product-85229-1.html?q=85229&source=header)
INTRODUCTION TO WIRE HARNESS :
WRINIG HARNESS: ASSEMBLY STRUCTURE -CONNECTOR
GEOMETRY PARAMETERS-POINT & CO-ORDINATE SYSTEM ( AXIS )
CONNECTOR CONNECTION POINT -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 0 -THIS POINT IS USED TO DEFINE THE CONNECTOR OF A CONNECTOR CLIP. THIS ONLY APPLIES TO CONNECTORS WHICH HAVE THE MOUTING FESTURE FOR A CONNECTOR CLIP.
CREATING THE CONNECTOR AXIS SYSTEM EXAMPLE - DEUTSCH / TYCO DT06-08SA-CE13 SELECT START- MECHANICAL DESIGN -PART DESIGN.
THE CONNECTOR AXIS SYSTEM SHOULD BE ON THE FRONT FACE OF THE CONNECTOR ATTACHED TO A POINT ON 0,0,0, COORDINATES, THIS POINT SHOULD BE IN THE CENTRE OF THE FRONT FACE AS THIS POINT WILL BE USED TO CONNECT THE CONNECTOR TO ANOTHER ELECTRICAL COMPONENT. SELECT THE CREATE AN AXIS ICON FROM THE WORKBENCH.
DEFINING THE CONNECTOR :
* SWITCH WORK BEACH FROM , MECHANICAL PART DESIGN, TO ELECTRICAL PART DESGIN,
* YOU MUST NOW DEFINE THE CONNECTOR CAD MODEL AS AN ELECTRICAL CONNECTOR .
* SELECT THE DEFINE CONNECTOR ICON FROM THE WORKBEACH.
* SELECT THE CONNECTOR CAD MODEL THAT YOU WANT TODEFINE AS ACONNECTOR:
* IN THE CONNECTOR DEFINITION BOX SELECT SINGLE INSERT CONNECTOR AS THE TYPE.
* ENTER THE PART NUMBER IN THE PART NUMBER FILED.
* NUMBER OF TERMINATION IS NUMBER OF POLES OF CONNECTORS .
* SELECT ,OK,,
* CERATING CAVITY CONNECTOR
HOW WIRES, FUSES , AND CONNECTORS WORK:
WITH THE EVER - INCREASING REUIEMENTS FOR COMFORT AND SAFETY IN PASSENGER VEHICLES THE DEMANDS ON THE ELECTRICAL POWER DISTRIBUTION INCREASE.
THE MAIN FUNCTION OF AN ELECTRICAL CAR SYSTEM IN THE FUTURE WILL BE TO PROVIDE A STABLE AND RELIABLE LEVEL OF ENERGY DISTRIBUTION . THAT INCLUDES AS ONE OF ITS MAIN CONCERNS , PREVENTING BATTERY BREAK DOWNS. FOR THIS REQUIREMENT TO BE ACHIEVABLE, IT IS NECESSARY TO KNOW THE STATUS OF HEALTH AND LEVEL OF CHARGE OF THE BATTERY. ANOTHER REUIREMENT IS THE POSSIBILITY TO REDISTRIBUTE ELECTRICAL POWER TO CRITICAL SYSTEMS E.G. SAFETY SYSTEMS HAS INCREASED DRAMATICALLY. CARS NOW HAVE LITERALLY THOUSANDS OF CIRCUITS .IN THIS WE, LL STUDY ABOUT CARS WRINING ,FUSES AND RELAY BOX AND HOW THEY FIT TOGETHER
.
WRIES:
A CAR 'S WIRING HAS TO DISTRIBUTE POWER FROM THE BATTERY TO DEVICES LOCATED ALL OVER THE CAR.IT ALSO HAS TO TRANSMIT DATA ON ADATA BUS , AS WELL AS A VARIETY OF DIGITAL AND ANLONG SSINGNALS FROM SWITCHES AND SENSORS.
THIS MEANS THAT THERE ARE MANY DIFFERENT TYPES OF WIRES IN YOUR CAR.SOME WIRES THAT TRANSMIT SINGNALS FROM SWITCHESS OR SENSORS CARRY ALMOST NO CURRENT. THOSE THAT PROVIDE POWER TO LARGE ELECTRIC MOTORS CARRY LOTS OF CURRENT . IF TOO MUNCH CURRENT GOES THROUGH A WIRE,IT CAN OVERHEAT AND MELT . THE AMOUNT OF CURRENT THAT AWIRE CAN HANDLE DEPENDS ON ITS LENGTH.COMPOSITION,SIZE (DIAMETER) AND HOW IT IS BUNDLED.
WIRES APPEARANCE:
MAIN WIRES (SINGLE COLOUR WIRE): BULK COLOUR OF INSULATING MATRIAL OF THE CABLE .THEY ARE USUALLY INTO GREEN ,RED,BLUE,YELLOW,BLACK AND WHITE.
* TRACER WIRES ( DOUBLE COLOUR WRIES): A THIN SPIRAL OR STRAIGHT MARKING OF A DIFFERENT COLOUR /COLOUR WITH RESOECT TO MAIN COLOUR, THEY ARE USUALLY INTO COMBINATION OF TWO HAVING STRIP OF OTHER COLOURS.
COLOUR CODES: (13313:1991)
THE INDIAN STANDARD WAS ADOPTED BY THE BUREAU OF INDIAN STANDARA, AFTER THE FINALIZED BY THE AUTOMOTIVE ELECTRICAL EQUIPMENT SECTIONAL COMMITTEE HAD BEEN APPROVED BY TRANSPORT ENGINEERING DIVISION COUNCIL.
THE GENERALLY RECOMMENDED COLOUR CODES ARE:
FOR THE OTHER CIRCUITS:
FUSE/FUSE-BOX:
FUSES ARE INCLUDED ON ALL YOUR CAR'S VARIOUS ELECTRICAL CIRCUITS TO PROTECT COMPONENTS FROM SURDES OF ELECTRICITY.TF TOO MUCH CURRENT FLOWS THROUGH THE CIRCUIT ,THE FUSE WILL BLOW INTERRUPTING THE CIRCUIT AND HALTING THE FLOW OF ELECTRICITY, PROTECTING THE COMPONENTS FURTHER DOWN THE CIRCUIT FUSES SHOULD BE SIZED AND LOCATED TO PROTECT THE WRIE THEY ARE CONNECTED TO.IF ADEVICE LIKE YOURCAR RADIO SUDDENLY DRAWS ENOUGH CURRENT TO BLOW THE FUSE, THE RADIO IS PROBABLY ALREADY TOAST. THE FUSE IS THERE TO PROTECT THE WIRE, WHICH WOULD BE MUCH HARDER TO REPLACE THAN THE RADIO.
MOST CAR'S HAVE TWO FUSE PANELS. THE ONE IN THE ENINE COMPARTMENT HOLDS THE FUSES FOR DEVICES LIKE THE COOLING FANS THE ANTI-LOCK BRAKE PUMP AND THE ENGINE CONTROL UNIT ALL OF WHICH ARE LOCATED IN THE ENGINE COMPARTMENT . ANOTHER FUSE PANEL ,USUALLY LOCATED IN THE DASHBOARD NEAR THE DRIVER'S KNEES, HOLDS FUSES FOR THE DEVICES AND SWITCHES LOCATED IN THE PASSENGER COMPARTMENT.
RELAYS:
RELAYS ARE REMOTE SWITCHES TAHT OPEN OR CLOSE AN ELECTRICAL CICUIT .FOR EXAMPLE , ONLY A LITTE ELECTRICITY IS NEEDED FOR THE HEADLIGHT SWITCH TAHT TURNS YOUR HEADLIGHTS ON AND OFF. WHEN YOU TURN THE SWITCH ON, INSTEAD OF SENDING POWER THROUGH THE SWITCH TO THE HEADLIGHTS DIRECTLY.THE SWITCH ACTIVATES A RELAY, SENDING A WHOLE LOT POWER TO THE HEADLIGHTS .
AUTOMOTIVE PIUG- IN RELAYS TE CONNECTIVITY
WHY FUSES BLOW :
SOMETIMES ,A MOMENTARY SUGE OF ELECRICITY COULD RANDOMLY CAUSE A FUSE TO BLOW. ONCE THE FUSE IS REPLACED ,THE CIRCUIT RESTORED,HOWEVED,IT'S MORE LIKELY TAHT A BLOWN FUSE IS CAUSED BY AN ELECTRICAL PROBLEM. IT COULD BE A FAULTY COMPONENT DRAWING TOO MUCH POWERA SHORT CIRCUIT OR A GROUND FAULT.
REPLACING BLOWN FUSES:
IF YOU 'VE IDENTIFIED AN ELECTRICAL PROBLEM ON YOUR CAR,LIKE A COMPONENT THAT,S STOPPED WORKING SUCH AS WIPERS,LIGHTS ,THE HORN,POWER WINDOWS AND DOORS.ETC.,CHECK THE ASSOCIATED FUSE FRIST. YOU CAN FIND A FUSE DIAGRAM ON THE LID OF YOUR CAR'S FUSE BOX AND /OR IN YOUR OWNER 'S MANUAL.
INSIDE THE FUSE, A SMALL STRIP OF METAL IS DESIGNED TO MELT IF THE CURRENT THROUGH THE FUSE EXCEEDS A CERTAIN AMPERAGE. IF YOU LOOK INSIDE AND THE STRIP OF METAL IS IN ONE PIECE, THE FUSE HASN'T BLOWN . HOWEVER,IF THE METAL STRIP IS BROKEN , THAT'S A BLOWN FUSE . TO REPLACE A BLOWN FUSE, JUST FIND A NEW FUSE OF THE SAME COLOUR AND AMPERAGE AND REPLACE IT IN THE CORRECT SLOT . YOU'LL OFTEN FIND SPARE FUSES IN THE FUSE BOX.
OVERVIEW OF POWER DISTRIBUTION :
TOGETHER THE FUSE, RELAY AND DRIVER CIRCUIT COMBINATION DOES NOT PROVIDE DIAGNOSTIC FUNCTIONALITY AND, DISSIPATING UP TO 4.5W OF ENETGY ,ARE WASTEFUL AND CONTRIBUTE TO HIGHER CO2 EMISSIONS. THEE/E ARCHITECTURE OF MOST OEMS IS MOVING TOWARDS AN APPROACH THAT HAS AN INCREASED NUMBER OF POWER DOMAINS .RETAINING TODAY'S APPROACH, THIS WOULD REQIRE A VERY LARGE CENTRALFUSE BOX OR MANY SMALLER FUSE BOXES SPREAD AROUND THE VECHICLE. TO ADDRESS SOME OF THESE CHALLENGES , POWER DISTRIBUTION NEEDS TO MOVE FROM A CENTRALISED TO A DECENTRALISED APPROACH .
SILICON ALTERNATIVES TO FUSE AND RELAYS: MOSFET TECHNOLOGY IS AN OBVIOUS CHICE AS A REPLACEMENT FOR THE RELAY -FUSE COMBINATION .
*CENTRAL RELAY AND FUSE BOX
*MULTIPLE SMALL POWER DISTRIBUTION CENTRES CONNECTED BY LIC OR CAN WITHIN A ZONE ARCHITECTURE APPROACH .
*ACCESSIBLE LOCATION TO EXCHANGE BLOWN FUSE.
*REDUCED WIRE HARNESS , OPTIMIZES SYSTEM COST AND WEIGHT. VULNERABLE TO MECHANICAL WEAR, DUST ,SHOCK,VIBRATION AND AGING .
*ENHANCED DIAGNOSTICS , PROTECTION AND EMC ROBUSTNESS.
WIRING HARNESS SCHEMATICS.
*WIRING HARNESS IS ONE THE MOST ESSENTIAL PARTS OF THE VEHICLE INDUSTRY. A WIRING HARNESS IS AN ORGANIZED SET OF WIRES, TERMINALS AND CONNECTORS THAT RUN THROUGHOUT THE ENTIRE VEHICLE AND TRANSMIT INFORMATION AND ELECTRIC POWER, THEREBY PLAYING A CRITICAL ROLE IN CONNECTING A VARIETY OF COMPONENTS. POWER AND INFORMATION TRAVEL THROUGH THIS NETWORK MUCH LIKE THE CIRCULATORY AND CENTRAL NERVOUS SYSTEMS OF THE HUMAN BODY . IT CONDUCTS ELECTRICITY FOR ALL ELECTRICAL LOADS ON A VEHICLE.
WIRING HARNESSES CONTRIBUTE TREMENDOUSLY TO MANUFACTURES, DEVELOPMENT AND ADVANCEMENT OF VEHICLE AROUND THE WORLD. AUTOMOBILES OR OFF - HIGHWAY VEHICLES ARE DRIVEN IN ALL KINDS OF ENVIRONMENTS. FROM CITIES TO MOUNTAIN VILLAGES, IN THE TROPICS AS WELL AS IN COLD CLIMATES. THIS MEANS WIRING HARNESS MUST OFFER SUPERIOR DURABILITY.
TYPES OF WIRING DIAGRMS
1.1 WIRING DIAGRAM .
A WIRING DIAGRAM IS A SIMPLE VISAL REPRESENTATION OF THE PHYSICAL CONNECTIONS AND PHYSICAL LAYOUT OF AN ELECTRICAL SYSTEM OR CIRCUIT. IT SHOWS HOW THE ELECTRICAL WIRES ARE INTERCONNECTED AND CAN ALSO SHOW WHERE FIXTURES AND COMPONENTS MAY BE CONNECTED TO THE SYSTEM.
FURTHERMORE ,WIRING DIAGRAMS TYPICALLY IDENTIFY EACH COMPONET WITHIN A SYSTEM BY ITS PART NUMBER AND ITS SERIAL NUMBER.
1.2 SCHEMATIC DIAGRAM:
A SCHEMATIC DIAGRAM IS A CIRCUIT WHICH SHOWS THE CONNECTIONS IN A CLEAR AND STANDARDIZED WAY. A SCHEMATIC DIAGRAM SHOWS THE COMPONONTS AND THEIR VALUES AND CONNECTIONS IN AN UNDERSTANDABLE MANNER. IT IS USUALLY USED TO COMMUNICATE OR INTENDED TO CONVEY THE CONNECTIONS AND WORKING OF THE CIRCUIT TO OTHER ENGINEERS.
1.3.PICTORIAL DIAGRAM.
A PICTORIAL REPRESENTATION OF THE WIRING DIAGRAM INCLUDES THE PHYSICAL REPRESENTATION OF THE ELECTRICAL COMPONOENTS LIKE CONNECTORS: THEY ARE MORE CONCERNED WITH HOW THE COMPONONENT ACTUALLY LOOKS IN PHYSICAL LIFE AND NOT WITH THEIR CONNECTIONS.
A PICTORIAL DRAWING IS SIMILAR TO A PHOTOGRAPH .IT SHOWS AN OBJECT AS IT APPEARS TO EYE, BUT IT IS NOT SATISFACTORY FOR SHOWING COMPLEX FORMS AND SHAPES.PICTORIAL DRAWINGS ARE USEFUL IN SHOWING THE GENERAL APPEARANCE OF AN OBJECT .
WRING DIAGRAM VS SCHEMATIC DIAGRAM
IT IS COMMON TO MOSTAKE A WIRINIG FOR A SCHEMATIC DIAGRAM OR VICE CERSA . THESE DIAGRAMS VISUALLY REPRESENT CONNECTIONS AND CIRCUITS, BUT THEIR FUNCTIONALITY IS ENTRIELY DIFFERENT . A WIRNG DIAGRAM ILLUSTRATES THE PHYSICAL COMPONENTS OF AN ELECTRIC CIRCUIT . ON THE OTHER HAND, A SCHEMATIC DIAGRAM DEPICTS THE FUNCTION OF THE CIRCUIT WITHOUT ANY CONCERN FOR THE CIRCUIT'S PHYSICAL LAYOUT. THE TABLE DOWN HERE WILL HELP YOU BETTER UNDERSTAND THE DIFFERENCE BETWEEN BOTH DIAGRAMS.
*READING SCHEMATIC WIRING WIRING DIAGRAM
THE ABILITY TO READ ELECTRICAL SCHEMATICS IS A REALLY USEFULL SKILL TO HAVE . TO START DEVELOPING YOUR SCHEMATIC READINNG ABILITES, IT,S IMPORTANT TO MEMORIZE THE MOST COMMON SCHEMATIC SYMBOLS. EACH PHYSICAL COMPONENT ( I,E RESISTOR,CAPACITOR, TRANSISTOR)HAS A UNIQUE SCHEMATIC SYMBOLS .
* THE MAIN GOAL OF THIS TUTORIAL IS TO SHOWN YOU THE ESSENTIAL SCHEMATIC COMPPONENTS YOU SHOULD KNOW. SCHEMATICS ARE OUR MAP TO DESIGING, BUILDING, AND TROUBLESHOOTING CIRCUITS. UNDERSTANDING HOW TO READ AND FOLLOW SCHEMATICS IS AN IMPORTANT SKILL FOR ANY ENGINEER.HERE ARE SOME OF THE COMMOMLY USED SCHEMATIC SYMBOLS.
*THE AUTOMOTIVE WIRING DIAGRAM IS A SIMPLE LAYOUT WHICH INCLUDES DIFFERENT TYPES OF ELECTRICAL DEVICES, SENSORS, ACTUATORS, CONTROLLERE AND ALSO CONNECTORS AND WIRES TO CONNECT THESE DEVICES TO THE ELECTRICAL POWER SOURCE WHICH IS NOTHING BUT THE BATTERY.
*THE AUTOMOTIVE WIRING DIAGRAM IS THE SAME AS THAT OF OTHER WIRING DIAGRAM BUT THE DIFFERENCE IS THAT HERE THE NUMBERE OF COMPONENTS WHICH ARE AVILABLE ARE MORE AND ALSO BECAUSE WHILE ROUTING THE WIRING THROUGHOUT THE VEHICLE THERE IS A SPACE CONSTRAINT WHICH MAKES IT EVEN MORE DIFFICULT TO UNDERSTAND .HERE IS ONE EXAMPLE OF A CAR WIRING DIAGRAM
FRONT,SIDE ,TOP,VIEW CONNTEORS
CONNECTORS PIONT CREATING FRIST STEP ,AXIS SYSTEM CREATING ,(X,Y,Z) VALUE SET AND POSITIVE SETP CREATING.
