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

In the diagram above, the electrical connectors are represented by numbers.

1. There are different types of connectors in ten different places.
2. Bundle continuity for the two created harnesses must be checked.
3. Once the two Harnesses have been created, the next step is to connect them electrically.
4. Examine Harness A and Harness B for bundle warnings.
5. Annotate all of the connectors in Harness A and Harness B.
6. The project's final goal is to convert the final harness file into IGS file format.

STEP 1:

Create geometric and electrical definitions for all electrical connectors that will be used in the wiring harness.

Connectors Used in Harness A

Connectors Used in Harness B

STEP 2:

Using the electrical harness workbench in CATIA V5, create harness A and harness B as shown below.

First, all of the connectors are placed in their proper positions. Second, bundle segments with branch points and branches are created between the connectors, as shown below.

Bundle diameters of 15mm, 10mm, 7mm, are assumed for various bundle segments.

Develop harness A and harness B using the CATIA V5 electrical harness workbench as illustrated below. The connectors are initially all positioned correctly. Then, bundle segments with points for branching and branches are built up between the connectors. Give the bend ratio as per requirment. Apply the protective coverings for both harnesses, keeping an end extremity of 20mm.

Harness A

Harness B

STEP 3:

Following the creation of Harness A and Harness B, the bundle continuity must be checked.

To begin, ensure that multi-branchable is selected, then navigate to Edit>Search>Advanced>Electrical Workbench>Type-Bundle Segment>Attribute-Fully Connected.

Selecting "TRUE" will display all connected bundle segments, while selecting "FALSE" will display all non-connected bundle segments.

STEP 4:

In this step, we must electrically connect Wiring Harness A and Harness B. A few steps must be taken in order to electrically connect the two harnesses.

To begin, create a new product file in CATIA and rename it "Assy Wire Harness."

Second, insert harness A and harness B into the newly created product file to create the final harness assembly. Once inside the electrical assembly design workbench, connect the male and female connectors as shown below.

Wiring Harness A and Harness B must be electrically connected in this step. The two harnesses need to be electrically connected, which requires a few procedures. Start by making a new product file in CATIA and renaming it "Harness A and B assembly”. The final harness assembly can then be built by adding harness A and harness B to the newly formed product file. Connect the male and female connectors inside the "Electrical Assembly Design" workbench as illustrated below.

STEP 5:

We'll check Harness A and B in this phase to see if there are any bundle warnings. Geometric bundle warnings for the bend radius, Vector position, and bundle diameter are normally shown. A yellow flash will appear in the tree structure adjacent to the problematic branchable if these inputs or values are wrong. We can solve the issue (if it exists) by introducing slack or by modifying the vector position for the segment point, depending on the route taken by the bundle segment.

STEP 6:

In this step, we will annotate all of the electrical connectors.

Annotations are used to display connector functions as well as extra information. They are defined in CATIA V5's Assembly Design Workbench.

First, we must select a plane on which to place the annotation.

We will label each electrical connector in this phase. Annotations are used to show extra information as well as connect functionalities. They are described in the "Assembly Design" workbench of CATIA V5. Prior to placing the annotation, we must choose a front plane, then place the annotation at the desired location (for all the connectors). Here, the annotations are placed as given in the question context.

Second, select the "flag note with ladder" function and then individually click on connectors. As shown below, provide the necessary information to all of the connectors.

After we've added annotations to all of the connectors, we should increase the font size of the annotations to make them more visible.

STEP 7:

The final step is to convert our Final Harness Assembly file into IGS format. To accomplish this, we must follow the steps outlined below.

Save the file in “igs” format by clicking on “File”, then “Save as”, then specifying the file type as “igs”, and make sure to tick “Save as new document”. Also, it is possible to name the file, as desired.