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

AIM:

The main objective is

• To Route the following harness layout in Electrical workbench and check the bundel continuity.
• To add Annotation to all connectors and to check for bundle warning
• To generate CAT.part of harness assembly and to convert in .igs format

INTRODUCTION:

Wiring Harness

A wiring harness is the complete electrical wiring system of a vehicle. Once the chassis structure is assembled, the wiring harness, brake and fuel lines are put in place. An extensive network of wires form the wiring harness of a car. A wiring harness is the electrical distribution system of a car.

Wire_A wire is a single strand of material that conducts electricity

Harness_Harness assemblies manufacturer usually make these out of aluminium or copper. Cable assemblies are a group of cables or wires that are wrapped in an outer layer of a different product to keep the cables together.

Connector

Connectors are the electro-mechanical devices used to form a continuous electronic signal to connect wire harnesses to a power source or circuit. On a basic level, connectors consist of male-ended plugs and female-ended jacks that can be joined together to relay an electronic signal. They are the familiar mating pair of polarized multi-pin connectors with wire leads. A male-ended plastic housing with release fits into a snap-mounted female-ended chassis mounting. The pair can be connected or disconnected easily and come in a variety of sizes, shapes, materials, quality, and dimensions—circular, header, pin, crimped, multitap—which are dependent on the application.

PROCEDURES:

HARNESS B

Every comonents shoud be an Electrical component to route the harness. The following steps are should be followed to define any component that are given as an electrical.

1. Create 3D object/Get from vendor

2. Define Geomentrical parameters

3. Define the 3d object as a connector

4. Define connection points

Geomentrical Parameters Definition

It's mandatory to create geomentrical parameters such as points and coordinating system in given comoponent to define connection points.

Above image shows pont creating on other side of connector to create bundle connection point.

conditions - Y axis should be in the mating direction

x axis should be in the locking mechanism direction

z axis should be in the direction towards top surface

Defining the connector to create connection points,

To create connection points we should have a electrical equipment like connectors, we should define the part or 3d object as an electrical device.

->Definition toolbar to define the given object as electrical

The above image shows The properties of electrical Device.

Connection Point definition

-> this is the toolbar in electrical part design to define connecting points.

Bundle Connection point

This is the point where bundle segment or wire point end when get routed to a connector. This point is known as Bundle Connection Point. At the time of defining bundle connection point, the number of terminals and a face is also provided as an input data.

Connector Connection point:

A connection point is a point in an electrical connector where a cable begins or ends. Electrical connectors are required to have at least one connection point with the route type set to Electrical. This defines the part as an electrical connector and provides information about the route

This point also used to make an assembly with other systems. This willl be defined by geomentrical parameters that we have already created.

• In Connector connection axis system, we have to always ensure that y-axis should be alwyas in the direction of mating axis of all the connectors.
• And x-axis should be in the diretion of locking mechanism and z-axis should be left-right side of the connector according to the orientation.

After defining the given component as electrical it will be added in geomentrical bundle to start routing.

The Harness Context Assembly

Geomentrical Bundle

Electrical Bundle

The harness context assembly:

This is the top_level product file that contains the harness geometrical bundle/assembly and the wire harness electrical bundle.

Geomentrical Bundle:

This sublevel product file is the wire harness product that contains all of the harness components i.e clips , supports, Connectors, splices,annotations and actual physical bunsle segments and branches.

Electriacl Bundle:

This sub level product file contains all of the electrical circuit information.

-> Toolbar to Define geomentrical bundle

By using the creation tool bar the product file can changed the geomentrical bundle, which is electrical product. It can be defined by a symbol which will be added to the product file.

Multi_Branching:

-> toolbar for multi branching

Bundles are developed between two electrical components by using bundle definition point.

The above image shows creation of bundle.

Bend radius_used to specify flexilibility of bundle. The radius should be minimum of 1.4 times of the bundle Diameter.

Build mode_ used to give extra length The place where the extra lengths are needed.

The above images shows, slecetion of connectors.

Tangent Management_ to create tangents on bundle based on connector ends.

Offset management_ used to specify the values for clearence between surface or along the surface.

mostly used in external reference to avoid fauling of bundle with support plates or other mating parts.

HARNESS A

Here, The steps to create Routing are same as above procedure ( i.e Harness B layout creation).

After defining the given component as electrical the connection points are created for routing.

Geomentrical Bundle creation

The above image clearly shows that all the required components are defined electrically and added to geomentrical bundle.

Now, all the connectors should be placed at desired locations with the help of manipulation in mechanical design work_Bench.

Multi Branchable_

Bundle Segments area created between connectors.

HARNESS A&B CONNECTION

Both can be connected by using connector connection point in electrical assembly workbench.

BUNDLE CONTINUITY CHECKING

For Harness A:

In the Edit tool bar we can get search option, its developed to figure out disconinuities in bundle segements.

Above image shows for FALSE, which means the links which are disconnected.

FROM ABOVE IMAGE WE CAN CONCLUDE THAT THERE IS NO DISCONTINUITY BETWEEN BUNDLE SEGMENTS

For Harness B:

RESULT_THERE IS NO BREAKING SEGMENTS OR DISCONTINUITY AMONG BUNDLE SEGMENTS

ANNOTATION

HARNESS A

HARNESS B

HARNESS A&B

BUNDLE WARNING

The above image shows that the tree structure have showing yellow colored warning on multibranchable, by using all errors can be identified and alerted.

Image_ after solving issues. Now, there is no yellow warning on tree structure.

RESULT:

CAT.PART file

CONCLUSION,

• Thus, The required Harness(A&B) routing has created for given layouts in Electrical workbench.
• Bundle continuity has cheked and Annotation created on all connectors.
• Bundle warning has successfully checked and resolved.
• The required CAT.Part has created and converted as igs.in file.