Wiring harness design in CATIA V5 - 3D modeling Week 4 Challenge
Ans 1
Objectives
- Downloading the following connectors cad data from the given link(www.te.com).
- Defining the Electrical Connector using the Electrical Part Design Workbench.
- Use the following connectors as shown in the layout diagram.
- Route the following harness layout in the Electrical workbench.
The layout to follow in this project.
Connector
It is an electro-mechanical device used to join electric terminations and creates electric circuits.
Deutsch DT06 – 08SA
https://www.te.com/usa-en/product-DT06-08SA.html
By using the above link we download the required part for our work
using the documents tab to download the cad file.
we can also see the properties of the connector before using it in our assembly by using the features option.
After downloading the required cad file we now move forward with the creation of the various parameters for our connector. For the creation of various parameters, we require the following point in the parts.
Bundle Connection Point
It is used to connect the wiring harness to the connector
for the creation of the bundle connection point, we create the point at the midpoint of the termination side of the connector.
using the between type of point definition to create the point at the midpoint on the face select two points and give the ratio as 0.5 to create the required bundle connection point.
Connector Connection Point
It is used to connect the other device or connector to the main connector
using the same process to create the point at the midpoint at the other face of the connector which is directly opposite to the bundle face.
Axis
we must create the axis for the proper facilitation or for the proper seating of other parts with the connector.
though these are not industry standards we need to be consistent with both mating parts in order to get proper assembly
Cavity Connection Point
It is used to provide the connection between the mounting system of connector clips with the connector. It is the same as the Connector connection point we also need to create an axis here similar to the connector axis but is an optional point we created it only when we required the mounting part.
After Creating the various parameter required in the connector we now need to convert the mechanical part into the electrical component for this we are going to use the electrical part design workbench.
To convert the required part into the electrical component we use the define connector tool option
By simply choosing the connector type and the number of terminations we can easily define the part as an electrical connector.
We now need to define the various point we created in the part workbench in the electrical definitions for that we use the bundle connection point to define the Bundle connection
In the representation, we select the face which is normal to the bundle entry in the point we use the bundle point, and again in the initial connection we select the face which is normal to the bundle entry.
We now need to define the various point we created in the part workbench in the electrical definitions for that we use the connector connection point to define the connector connection
for that, we choose the representation as our already created connection point in the contact we choose which will go to be in contact with other mating parts we choose the coincidence axis as the Y axis where our parts move in and out for the assembly or in case of disjoining the parts and in the end we choose the orientation axis x-axis.
Similarly, we can use the same steps again for the other required parts.
DT06-6S
https://www.te.com/usa-en/product-DT06-6S.html
DT06-4S
https://www.te.com/usa-en/product-DT06-4S.html
DT06-2S
https://www.te.com/usa-en/product-DT06-2S.html
After defining all the parts electrically we now move forward to save them in the catalog.
catalog
It is a document that keeps a list of references of other Catia parts and features which we can use these part whenever required.
Step 1
Clicking the New option present in the file tab and using the CatalogDocument in the new option to form the new catalog file for the same.
Step 2
Using the add family option to open the new tab for the creation of a catalog
Step 3
Giving the name of an electrical component for example connector and giving the type in the family definition as Electrical to save our electrical component in this catalog.
opening the options tool by drop downing the tool option and clicking on the equipment and system to further open the new options.
adding the Electrical mapping option to add the already created in the connector catalog.
for the storage of cad parts of electrical components
for storing the cad parts the storage option and giving the location of the catalog file in the catalog option and choose the required family in the family tab.
using the add file option in the mapping tab and selecting the required catalog file to add and then clicking ok to get the required catalog for further use in the future.
After saving connectors in the catalog, we move forward to assemble them.
So for harness assembly, it contains many assembly files such as
Harness Context Assembly
As the name suggests, it is the assembly file that contains environmental data that provides information about the surrounding parts while assembling the wire harness, and before submitting the assembly file, we have to remove any kind of link between the surrounding electrical parts.
Geometric Bundle
It is the sub-level product file and contains all the harness products, i.e., clips, supports, connectors, grommets, and actual physical bundle segments and branches.
Inserting the components into the assembly
For inserting the components that are already electrically defined in the assembly, we use the browse catalog option from the browse catalog toolbar.
After opening the browse catalog toolbar, we can select the required connector from the list.
We can select the required number of connectors by double-clicking the required connector.
Hence, after selecting the required connectors for the required numbers, we now move on to the manipulating toolbar to properly place the required connectors for their respective distances and for the required orientation.
After placing the connectors in their required places, we now move on to convert the part assembly into the electrical harness assembly by using the electrical harness assembly workbench.
After going into the electrical assembly design, we now use the geometric bundle option to convert the normal assembly into the electrical assembly. We ensure the proper change of assembly into electrical by ensuring the change of the tool icon into an electrical tool icon.
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For the making of the wire harness, we use the multi-branch document tool for the formation of the wire harness between the connectors.
A new window pops up named Branch Definition to give the diameter and bending ratio as the input for the new branch, where the bending ratio generally lies between 1.4 and 1.5 from the empirical relation.
After giving the required parameter for the branch, we now move forward with the route definition to provide the proper route to the required bundle.
Here in the routed objects, we select the electrical components into which we require to make the bundles.
For splitting the bundle into two, we use the add branch point tool to divide the required bundle.
providing the length as an input into the branch point tool as per the requirement
In the above image, we see the bundle, which is green in color, splintered into two parts at a distance that is required as per the question
Similarly, we are now able to create the bundle between the different connectors as per the diagram mentioned in the question.
We now move forward with the formation of the protective covering for the required bundle.
Step 1
Clicking the New option present in the file tab and using the CatalogDocument in the new option to form the new catalog file for the same.
Step 2
Using the add family option to open the new tab for the creation of a catalog
Step 3
Giving the name of an electrical component for example Slit_Cot_Tube and giving the type in the family definition as Conduit to save our electrical component in this catalog.
Conduit
Electrical conduits are flexible, resilient, corrugated cylindrical protectants that encase your cables to protect them from damage.
For the making of the electrical conduit, we are using the electrical part design workbench.
For the formation, we are using the define protection part tool.
In this, the details such as inner diameter, thickness, and bending radius are given, while the bending radius depends heavily upon the flexibility of the conduit; if the material is more flexible, the bending radius would be less, and vice versa; but generally, the imperial relationship suggests choosing the bending radius as 1.5 times the outer radius of corrugated tubes. while choosing the conduit type as a corrugated tube and keeping the option of light geometry set to on.
Repeat the same for the rest of the tubes as per the mentioned dimensions.
for storing the cad parts the storage option and giving the location of the catalog file in the catalog option and choose the required family in the family tab.
After saving the slit tubes in the cot tubes catalog, we now use the option of a protective covering tool for providing the covering on the bundles.
selecting the required branch onto which we will provide the protective covering.
browse the catalog from the browse catalog option in the protective covering window
From the required list, choose the slit tube as per the requirement for the protective covering, where the numbers at the end suggest the diameter of the slit tube.
By clicking the start and end extremities, we can choose the length of the protective covering as mentioned in the question.
After providing the length of the extremity at the opposite end, we have our respective protective covering for the required bundle.
