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

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

Aim:

1) To Route the following harness layout in the Electrical workbench.

2) Add protective covering on all branches connected to DT06-2S & DT06-4S connectors.

Input:

CAD data of the following Connectors:

● DT06-4S

● DT06-6S

● DT06-2S

● DT06-08SA

Connectors Layout Design:

Steps to be followed:

1. Download connector 3D data from www.te.com

• DT06-4S
• DT06-6S
• DT06-2S
• DT06-08SA

2. Converting the Mechanical part into the Electrical part for that I had followed the following steps.

Geometry Parameters:

Points - connector connecting point, bundle connecting point

Coordinate System (Axis) - for defining coincidence direction and locking direction
Connector Connection Points - This point is used for the connection of one connector to another connector.
Bundle Connecting Point - This point defines where the harness bundle segment point will end when routed to the electrical connector.
Cavity Connection Point (Optional) - This point is used to define the connection of a connector to a connector clip. This only applies to connectors that have the mounting feature for a connector clip.

Connectors 1: C-DT06-08SA

• Import the downloaded step or igs file into the CATIA mechanical
• part workbench and save as cad part.
• Define the Bundle Entry Point.

● Define the Connector Connection Point.

● Define Connector Connection Axis. Y-Axis should face the other mating part/direction and X-Axis should face the lock.

● Now switch to the Electrical Part Design Workbench and define the connector using Define Connector Command with Name and No. of Terminals.

● Define the Bundle Connection Point. Face as Representation, Bundle Entry Point as Point, and Same face as Representation for Initial Condition.

● Define the Connector Connection Point. Connector Connection Point as Representation, Mating Face as Contact, Y-axis as Coincidence, and X-Axis as Orientation.

So likewise, all the connectors are electrically defined.

Now Create the Electric wire harness context assembly and Geometric bundle as a subassembly containing all the electric parameters as shown below,

Preparation of Harness Assembly

As we are done with Wiring harness component designs, It is time to Prepare Product assembly for the given harness.

Wiring harness Product assembly contains:

The Harness Context Assembly - this is the top-level product file that contains the harness Geometrical Bundle/Assembly and the wire harness electrical bundle.

Geometrical Bundle - This sub level product file is the wire harness product that contains all of the harness components i.e., clips, supports, connectors, splices, grommets, annotation and actual physical bundle segments and branches.

Electrical Bundle - This sub level product file contains all of the electrical circuit Information

• Create the Electric wire harness context assembly and Geometric bundle as a subassembly.
• Add all connectors which are electrically defined to the Geometric bundle assembly.
• Then define this Geometric bundle assembly as electrically, for that we need to switch to an Electric harness assembly workbench.

• select Geometric Bundle then click on Geometric bundle assembly (In specification Tree)
• Now, to position all the connector as given in input file,
• Create an environment on which the bundle assembly will be placed.
• Draw the sketch as given dimension in input just for reference purpose.
• Switch to Mechanical assembly workbench, Position the connectors by using Manipulation, snap, smart move and compass commands.

• Connect and Disconnect Electrical Devices:
• If there are any assemblies that need to be assembled before routing like Connector with Mounting Clip or Connector with back shell. Then Assemble them using "Connect Electrical" Devices

• Defining the Wiring Harness Routing:
• Now switch to Electric harness assembly workbench
• select multi branchable documents

• In the Branch Definition Box(Ref Below Image) ,describe all the required parameters 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

• Then click on route definition
• select connectors in between we want to create branches.

• To add branch point

• select the branch then give ratio or dimension for the point
• Final wire harness routing

• Now to create protective covering on all branches
• switch to electrical harness assembly

• select protective covering then select branch - select catalog - select appropriate slit cot tubes - give extremity at start and end - ok

Note: I am not able to upload file so I attached as a gdrive link.

https://drive.google.com/file/d/1Q1bufMxz7I_T0RJJCLKT9EhLVeD9HL70/view?usp=drive_link