Wiring harness design in CATIA V5 - 3D modeling Week 4 Challenge

AIM: To Route the following harness layout in Electrical workbench.

Add protective covering on all branches connected to DT06-2S & DT06-4S connectors. Keeping end extremity at 30mm (from connectors end)

Flow chart of wiring and harness assembly

• Identifying Harness Assembly components
• Defining all Harness components as Electrical
• Preparing Harness Assembly
• Define Assembly as Electrical Assembly
• Route Bundles and give protective coverings

Defining Connector features

• The specified connectors are downloaded from te.com. In the part design workbench, the centre point and axis system to the wire-bundle inserting end and connector connection end are provided. The axis must be given in a specified way:
• Defining Connector connection Axis
• X-axis: Towards the locking mechanism of clip.
• Y-axis: Towards the front face of connector.

Once the axis is defined, in the electrical part design workbench,

• Using the define connector tool, convert the mechanical part into connector.
• Now connector connection point, bundle entry point, and cavity mounting point is defined.
• Once the electrical properties are given new properties will be shown in the design tree.

Connector Connection Point – The Centre of axis system is chosen as the representation

Contact is the face of the connector that will mate. Coincidence is chosen as Y-axis. Orientation is chosen as X-axis

Bundle Connection Point

DT Series Connectors:
The Deutsch DT series general purpose connectors will provide reliability and performance on the engine or transmission, under the hood, on the chassis, or in the cab.

The DT connectors are used in harsh environment applications where even a small degradation in connection may be critical. Thermoplastic housings offer a wide operating temperature range and silicone rear wire and interface seals allow the connectors to withstand conditions of extreme temperature and moisture. The DT series offers the designer the ability to use multiple size 16 contacts, each with 13-amp continuous capacity, within a single shell.

• Technical Specification
  Voltage: 250 VAC/VDC, Current (Amp)
• 14 to 20 AWG: 13 A; 16 AWG [1.00 mm²]: 13 A to 7.5 A current.
• Operating at temperatures -55°C to +125°C.
• Insulation Resistance is 1000 megohms minimum at 25°C.
• Materials: Grommet: Silicone rubber; Seal: Silicone rubber; Threaded Inserts: Stainless steel; Shell: Glass filled PA; Wedge-locks: Glass filled PBT

Back-shell: Back-shells are snapped onto connectors. Straight (180°) and right angle (90°) versions are available.
Mounting Clips: Mounting clips are installed on the receptacle to mount DT series connectors. The clips are available for several configurations and in plastic, stainless steel, or steel with zinc plating.



DT Series Part Configuration

DT06- Series

DT06-4S

DT06-6S

DT06-2S

DT06-08SA

Using the Multibranch-able to add all the necessary branches, branch points in the wiring and harness assembly.

Branch definition

While defining the Branch, The diameter has to be specified. Next Bend radius has to be specified. A nominal ratio of 1.4 is taken. Further, if there is a reqiurement of slack, it can be provided. Next route definition has to be specified.



Route Definition

The connector is chosen as the first object and either another connector is chosen as the second object/reference or a branch point is chosen as the second object.
Using the tangent direction, Harness bundle can be routed accordingly. Also external geometrical references can be given for tangent direction

Connector-Connector routing



Connector-Branch point routing

Bundle Segment Definition


Corrugated Tubes from Catalogue


Hiring Harness Assembly with Corrugated tube protective layer.





Tree Structure