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

AIM - Downloading connectors cad data & define it as Electrical Connector using Electrical Part design Workbench. Define all the necessary properties to Connectors. Routing between the connectors is done using wiring harness assembly .

HARNESS DESIGN PROCESS – Using Physical Architecture, Harness routing and packaging is designed.

STEP 1 - ­­Identify the harness assembly components

STEP 2 - define all harness components as electrical

STEP 3 - prepare harness assembly

STEP 4 - define assembly as electrical assembly

STEP 5 – change tool setting as required

STEP 6 – start routing the bundles

WIRING HARNESS ASSEMBLY STRUCTURE –

CONNECTOR DEFINITION –

STEP 1 – Create / download connector 3D

STEP 2 – Create required geometrical parameters

STEP 3 – Define part as connector

From electrical part workbench select part as a connector, which states part functions as electrical component.

STEP 4 – define Bundle connection point

Create a point on the wire entry side with reference as face normal to the bundle connection point

This point defines where the harness bundle segment point will end when routed to the electrical connector.

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

STEP 5 - define connector connection point

Geometry parameters – create a point on the face of the mating side and create a coordinate system at a point created with Y-AXIS should be pointing towards the front face of the connector, same direction as the harness to the connector, X-AXIS should be pointing in the direction towards the locking mechanism of the clip and Z-AXIS should be pointing across the connector from left to right. Can use your own but it should be consistent for mating connectors.

Connector connection point – this point is used for the connection of one connector to another connector.

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

Catalog – create a catalog for connectors after it is electrically defined

Routing – it is done by wiring harness assembly. Prepare product assembly for given harness after designing wiring harness component designs.

Wiring harness product assembly Ensure that all harness components that are needed in assembly are electrically defined with all required parameters before adding them in assembly. All components are placed at desired locations

Branching – creating the wire harness bundle segments by using electrical harness assembly workbench.

Before branching ensure harness geometrical bundle highlighted. It means converting geometric components to electrical component.

Select Create multi branchable document icon to start branching between the connectors.

Input all the required parameters in the branch definition box

Bend radius is set to 1.4 or greater than 1.5 of diameter of branch i.e,10mm for branching and 5mm for the connectors branched from branch points and ensure that build mode is set to slack.

Create a branch point 100mm from right of DT06-08SA and 250mm from left of DT06-6S and with these branch points branch the connectors.

Create a branch point 100mm from left of DT06-4S and branch the connector with this point.

Creation of protective coverings for the branching. Using COT of dia 15mm for branching and 10mm for the connectors branched from branch points