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

AIM:

1. Route two electrical harnesses per the given layout and interconnect them as a single harness assembly
2. check for bundle continuity, and bundle warnings, and then provide annotations for the final harness assembly.

OBJECTIVE:

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

IMAGE 1: Shows the layout of two Harness A and Harness B

The electrical connectors are represented by numbers in the above figure. There are 8 different types of connectors at 10 different locations.

    2. Bundle continuity has to be checked for the two created harnesses.

    3. After the two Harnesses are created, the next objective is to have them interconnected electrically.

    4. Check for bundle warnings in Harness A and Harness B.

    5. Add annotations to all the connectors in Harness A and Harness B.

CONTENT:

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

STEP 1

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

YDTS26F15-35SNV001

TREE STRUCTURE

DT06-3S-CP01

TREE STRUCTURE

DT06-08SA-CE04

TREE STRUCTURE

DT06-08SA-EP06

TREE STRUCTURE

DT06-08SA-CE13

TREE STRUCTURE

DT06-08PA-CO17

TREE STRUCTURE

2-174357-2

TREE STRUCTURE

CONNECTOR CLIP

 

TREE STRUCTURE

 

DT06-08SA-CE01

TREE STRUCTURE

HARNESS A

After all the connectors are defined, the workbench was switched to Electrical Harness Assembly where Geometrical Bundle was activated. All the connectors were routed using the Multi-Branchable Document command. 

TREE STRUCTURE

HARNESS B

After all the connectors are defined, the workbench was switched to Electrical Harness Assembly where Geometrical Bundle was activated. All the connectors were routed using the Multi-Branchable Document command. 

TREE STRUCTURE

HARNESS ASSEMBLY

BUNDLE WARNING

• In this step, we will be checking the bundle warning in Harness A & B.
• Geometrical bundle warnings are shown for bend radius, bundle diameter and vector position.
• So if there is any incorrect value or input regarding these factors then yellow colored flash wiil be appear in the model tree structure next to the branchable with problems.
• Here, I have one error in Harness B in branchable 4 as below.

 

• This error can be corrected by changing routing direction of DT06-08SA-EP07, for that we have to select 'Reverse Tangent' option so error will be solved and that yellow flash will also disappear as below image.  

CONNECTIVITY CHECK 

ANNOTATIONS

• In this step, we have to add annotations for all the connectors in mechanical assembly design workbench.
• Annotations are used for giving connector name, functions etc.
• For this, we have to select plane where annotation will be placed. I have selected front plane.
• We should make sure that the geometrical bundle is active before selecting the annotation plane.
• So after giving annotations to all connectors, the whole assembly will look as below.

 

CONVERT AS A PART BODY AND SAVE AS IGS FORMAT

• Now, in this step we have to convert final harness assembly file into IGS format. So for that we need to follow below steps.
• Mechanical Assembly Design workbench>Tools>Generate CAT Part from product.
• Once the CAT part is created, the whole product file is converted into a single part.
• Now, whole file is converted into the IGS format and we can see all the harness assembly is looking in grey color.
• If we need to change color as before in yellow, we can go back and give yellow color to each bundle segment.

• To save CAT part file as IGS file, we have to use 'Save as' option as shown in below image.

So in this way, we have done with the harness routing and interconnection of both the harness A&B according to given layout. Both the harnesses are checked and corrected for bundle continuity, bundle warnings, annotations are added for all the connectors and at the end whole CAT part file is converted into the IGS format.