Wiring harness design in CATIA V5 - 3D modeling Week 5 & 6 Challenge

OBJECTIVE-

• The objective of this project is to first route the two Harness A and Harness B as per the given harness layout.

all the connectors are placed at their desired locations. Second, bundle segments are created between the connectors with branch points and branches as shown below.

Bundle diameter is assumed to be 20mm, 15mm, 10mm, and 5mm for different bundle segments. Bend ratio is given as 1.4 and slack is given as 0% for all the bundle segments.

CONTENT-

The following steps are to be done to complete this project.

Define all the electrical connectors geometrically and electrically so that they can be used in the wiring harness.

Final routed Harness A

As per the image attached below Harness 1 is created. All the connectors are downloaded and all the necessary electrical parameters of all the connectors are defined and assembled as shown in the image in electrical harness assembly and 3D annotations are added.

Final routed Harness B

As per the image attached below Harness 2 is created. All the connectors are downloaded and all the necessary electrical parameters of all the connectors are defined and assembled as shown in the image in electrical harness assembly and 3D annotations are added

In this step, we have to interconnect the Wiring Harness A and Harness B electrically. There are a few steps that have to be followed to connect the two harnesses electrically.

First, make a new product file in CATIA and rename it as "FINAL HARNESS ASSEMBLY". Make sure to open the three windows vertically as shown below.

As per the image attached below Harness A&B are electrically connected using electrical assembly design created.

As per images attached below the harness bundle warnings are due to improper bend radius and improper bundle direction respectively can be corrected by giving proper bend radius and changing bundle direction respectively.

As per images attached below the harness bundle warnings are due to improper bend radius and improper bundle direction respectively can be corrected by giving proper bend radius and changing bundle direction respectively.

As per images attached below the harness bundle warnings are due to Elecrtical curve switch to be regulate and improper bundle direction respectively can be corrected by giving proper bend radius and changing bundle direction respectively.

Once the CAT part is created the whole product file is converted into a single part. At this stage, it can be noticed that all the bundle segments are grey in color. So, we will go back and add green color to each bundle segment so that they look same as the Final Harness Assembly.

Annotations are used to show connector functions and additional information. They are defined in Assembly Design Workbench of CATIA V5.

• First, we have to choose a plane on which the annotation will be placed. Here we will be choosing the front plane as shown below for Harness A. We should make sure that the geometrical bundle is active before choosing the annotation plane.
• Second, select "flag note with ladder" function and then click on connectors individually. Give the necessary information to all the connectors.
• After annotations are added to all the connectors we should change the annotation font size and color so they are easily visible.

CONCLUSION- Routing of the two electrical harnesses as per the given layout was achieved and interconnection between them as a single harness assembly was established. Both the harness were checked and corrected for bundle warnings and bundle continuity. At the very end, annotations were added to all the connectors and the final harness assembly file was converted into IGS format.