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

AIM:

To Route the following harness layout in Electrical workbench. Use the connectors provided. Check the bundle Continuity. Add annotation to all connectors. Check for the bundle warning. Generate CAT.part of harness assembly and convert is in. igs format.

STEP-1:

We Have download connector from given source as igs file and open into Catia V5. and save as a .CATpart.

• Go To the Part design workbench & Taking A middle Point From The Connector Connecting Side As Well As Bundle Connecting Side.
• Taking the axis Origin of Connector connecting Point.
• Adjusting the y-axis is normal to the face of connector connecting Point & X-axis would be locking side & Z-axis would be Up or down side.
• Then go to the electrical part design workbench after that defined it as a connector & Add no of terminals it has & defining the connector connection point As well as bundle connection point with respect to their faces & Respresentations.
• Do this for all other given connector.

Image mention below.

Connector-1 of Harness B :

Connector-2 of Harness B :

Connector-3 of Harness B :

Connector-4 of Harness B :

Connector-5 of Harness B :

Connector-6 of Harness A :

Connector-7 of Harness A :

Connector-8 of Harness A :

Connector-9 of Harness A :

Connector-10 of Harness A :

Create the separate catalogue for the connector and add them all into the connector catalogue. image shown in below.

STEP-2:

Create the basic layout for the routing the connector in the desired poisition. image mention below.

BASIC LAYOUT FOR HARNESS-A

BASIC LAYOUT FOR HARNESS-B

ROUTING ASSEMBLY CREATION OF HARNESS A AND B:

• we have to create Harness A and Harness B by using electrical harness assembly.
• Then go to the electrical harness Assembly Define the product as an geometric bundle.
• And then go the multibranchable point Route the bundles And suitable break points with respect to the given Diagram.
• And create bundle segment according to the diameters assumed as 15mm and 10mm. Image mention below.

Electrical Routing of harness Assembly A :

Electrical Routing of harness Assembly B:

CHECK THE BUNDLE CONTINUITY:

• 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.

For harness-A:

For harness-B:

INTERCONNECTION OF HARNESS A AND B:

• 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.
• 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.

Image mention below.

STEP-3:

CHECK FOR THE 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, we have one error in Harness B in branchable 3.

Image mention below.

When the error comes it show the red light. I marked in above image. when it shows the red light then we have the error in the red light.

Error in the above image was direction of the tangent was wrong in the bundle.

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. and it show the green light when the error was corrected. image mention below.

STEP-4:

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. In below image, we have selected front plane.

And the click the flage not with leader option to give name to the connector as connector 1 , 2 etc. image mention below.

We can change a font, font color and font size by going into the properties as shown in below image.

STEP-5:

Generate CAT.part of harness assembly and convert is in. igs format:

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

Image mention below.

After save as the part as the .igs file. image mention below.

CONCLUSION:

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. and annotations are added for all the connectors and at the end and whole assembly was converted into the .Catpart file and futher is converted into the .igs format.