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

Let, we have provided the harness layout as below and accordingly we have to route it. For that we have to make assumption for harness bundle diameters and use DT connectors.

Step 1: We have to first define all the connectors geometrically and electrically as shown in below images.

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 branch points required and create bundle segment according to the diameters assumed as 10mm and 5mm.

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

Step 4:

• In this step, we have to interconnect both Harness A & Harness B.
• For that, we have to create new product file and can give name as Assembly.
• Then, copy both harnesses and paste it in newly created product file or call both harnesses in mechanical assembly design as below image.

• We have to go in Electrical Assembly Design to connect both the harnesses electrically. So for that, select the option 'connect electrical devices' and both the harnesses will get connected electrically as below.

• As shown in below image, male connector should have to be 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 yellow colored flash wiil be 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 routing direction of point 4, for that we have to select 'Reverse Tangent' option so error will be solved and that yellow flash will also disappear as below image.  

Step 6:

• 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. In below image, we have selected front plane.

• We should make sure that the geometrical bundle is active before selecting the annotation plane.
• We can change a font, font color and font size by going into the properties as shown in below image.

• So after giving annotations to all connectors, the whole assembly will look as below.

Step 7:

• 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 green, we can go back and give green 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.