Student projects/CATIAChallengeWiring harness design in CATIA V5 - 3D modeling Week 4 ChallengeKKokul S7 Jan 2023CATIADESIGN Wiring harness design in CATIA V5 - 3D modeling 1. Route the following harness layout in Electrical workbench. Make assumption for harness bundle diameters. Use Following connectors as shown in layout diagram. Add protective covering on all branches connected to DT06-2S & DT06-4S connectors. Keep end extremity at 30mm (from connectors end) Download connector 3D data from DT06-4S DT06-6S DT06-2S DT06-08SA DESIGN OF WIRING HARNESS ROUTING IN CATIA V5 INTRODUCTION The wiring harness routing consists of an assembly of the geometrical bundle and electrical bundle. For the mechanical wiring harness, assembly of the geometrical bundle is the main component. For assembly of the geometrical bundle, the connectors, clips, grommets must be electrically defined before entering into the WIRING HARNESS ASSEMBLY. In the present project, the wiring harness for the following mentioned figure ASSIGN ELECTRICAL PROPERTIES TO CONNECTORS The required connectors are downloaded from te.com. The electrical properties are given to all the connectors using electrical part design. 1) Go to electrical part design. 2) Define the connectors by using the CONNECTORS command. 3) Define the CONNECTORS CONNECTION POINT and BUNDLE CONNECTORS POINT to the CONNECTORS. Objective: To Route the harness layout in Electrical workbench based on the given input.To add protective coverings on all branches connected to DT06-2S & DT06-4S connectors. Keep end extremity at 30mm (from connectors end). Steps Involved: 1.Preparation of Harness Assembly: Create a master product file(Harness Context Assembly) and two sub-level product files named Geometrical Bundle & Electrical Bundle respectively.(Ref Below image). Insert all the required Surrounding Part data into the Master Product file. Save the master product file in a desired location. 2.Creating the Wire harness Geometrical Bundle: Once Geometrical Bundle is created, then open it in a new window. Select the "Geometrical Bundle" command and then click on Product Icon in Model tree to convert it into an Electrical Assembly.(Ref Image below) 3.Inserting Harness Components into Geometrical Bundle:Before Inserting the components, ensure that all the required components have been electrically defined. Once the required components were defined electically, then insert them using Catalog Browser command or using existing component command(ref below image) 4.Positioning the Inserted Components:Before start routing, ensure all the components in it's desired location according to surrounding data. If not then place and position the components by using any of the following commands like Manipulation, Translation or Rotation,Snap,Smart Move,Compass.(ref below image) 5.Connect and Disconnect Electrical Devices: If there are any assembly that need to be assembled before routing like Connector with Mounting Clip or Connector with backshell. Then Assemble them using "Connect Electrical" Devices 6.Defining the Wiring Harness Routing: Creating Wire Harness with Single Branch: Switch to Electrical harness Assembly Workbench. Select Multibranchable Document Icon. In the Branch Definition Box(Ref Below Image) ,describe all the required paramters like Diameter,Bend Radius(>1.4),Build mode(slack,Length,Bend,Straight Bend). Click Route Definition and select the two components that you need to route. Click OK Creating Wire Harness with Multible Branches: Switch to Electrical harness Assembly Workbench. Select Multibranchable Document Icon. In the Branch Definition Box ,describe all the required paramters like Diameter,Bend Radius(>1.4),Build mode(slack,Length,Bend,Straight Bend). Click Route Definition and select the two components that you need to route. Click OK. Once the Multibranchable is created, Click Add branch point command and define the point on the main branch where the Harness Branch needs to be created. Repeat the steps from "c to e" Add protective covering on the required branches by using Protective Covering Command and mention the start and end extremity points.= CREATING WIRING HARNESS 1) Create the assembly of geometrical bundle products in CATIA V5. 2) Open all the required connectors into the geometrical bundle assembly product. Note that all the connectors must be electrically defined. 3) As mentioned in the figure, the connectors are placed al the required positions using the SNAP, SMART MOVE, COORDINATE SYSTEM, and MANIPULATION COMMANDS. 4) Now enter into the WIRING HARNESS ASSEMBLY workbench. 5) Click on MULTI-BRANCHABLE DOCUMENT, give the branch diameter and the bend ratio. Open the route definition and connect the bundle connection points. 6) To give the routing from main branch use ADD BRANCH POINT at the required location and give the sub-branches. 7) Now, add the corrugated tubes which are created and saved in COT_TUBES catalogue. 8) Cover all the branches with corrugated tubes. Give the extremity point from 30 mm. CONCLUSION Thus, the Wiring Harness Layout has been designed with the given inputs and the protective coverings also added on the required branches(ref below image) The required wiring harness routing has been developed in the CATIA V5.