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

WIRING HARNESS DESIGN IN CATIA V5 - 3D MODELING WEEK 5 & 6 CHALLENGE

AIM-

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

STEP 1:

We have to first define all the connectors geometrically and electrically

STEP 2:

Now, we have to create Harness A and Harness B by using electrical harness assembly as shown in below image.

First, we will locate all the connectors at their desired position, add the branch points required and create bundle segments according to the diameters assumed as 18mm and 12mm.

Harness B Routing

Harness A Routing

STEP 3:

• Now in this step, we have to check bundle continuity in both Harness A and Harness B.
• So for that, go to Edit>Search>Workbench-Electrical>Type-Bundle segment>Attribute-fully connected.
• We will get one window, in which selecting the True option will show all the connected bundle segments while selecting the False option will show all the non-connected bundle segments.
• Now, we will check for True conditions and search for results.
• All the bundle segments are showing connected. So there is bundle continuity in both Harness A & Harness B as shown below images.

STEP 4:

• In this step, we have to interconnect both Harness A & Harness B.
• For that, we have to create a new product file and can give the name HARNESS Assembly.
• Then, copy both harnesses and paste them into the newly created product file or call both harnesses in mechanical assembly design as in the below image.
• 
• select the option 'connect electrical devices' and both the harnesses will get connected electrically as below.

• As shown in the below image, the male connector should have been inserted into the female connector.

STEP 5:

• 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 a yellow colored flash will appear in the model tree structure next to the branchable with problems.
• Here, we have one error in Harness B in branchable 3 as below.

• This error can be corrected by changing the routing direction of point 4, for that we have to select the 'Reverse Tangent' option so the error will be solved and the yellow flash will also disappear.

STEP 6:

In this step, we have to add annotations for all the connectors in the mechanical assembly design workbench

for example connector 1,2 etc.

STEP 7:

Add cot tubes to the wires connected to the connector with varying diameters to the Harness A and B.

The above image is fully connected wires checking.

• Now, in this step, we have to convert the final harness assembly file into IGS format.