Wiring harness design in CATIA V5 - 3D modeling Week 7 Challenge

Wiring harness design in CATIA V5 - 3D modeling

AIM : To prepare a flattened view of a previously created harness assembly.

OBJECTIVE : The objective of this project is to create a flattened view for a harness assembly and then place it on the drawing sheet. It is desired that the bundles with protective coverings are represented with different visuals on the drawing sheet.

Route the following harness layout in Electrical workbench. Make assumption for harness bundle diameters. Use Following connectors as shown in layout diagram.

Add protective covering on all branches connected to DT06-2S & DT06-4S connectors. Keep end extremity at 30mm (from connectors end)

Download connector 3D data from www.te.com

• DT06-4S
• DT06-6S
• DT06-2S
• DT06-08SA

DEFINIG ELECTRIC PARAMETER FLOW CHART :

Routing Procedure :

• First download the given CAD data.
• Define it as electical connector or cavity depending upon how the component is going to work.
• Then create a mounting point on the connector and create axis system on the point.
• Make sure that the direction of the axis system should be lie according to the conectors.
• Here X is point toward the left because the locking mechanism is in the sides of the connector and Y should point the direction from where the bundle and mating part is going to connect. According to the X and Y we can direct the Z.

CONNECTOR DEFINATIONS IN CATIA V5 :

1. Deutsch DT06 – 08SA

Connector connection point:

Create midpoint on the contact face which will be normal to wire bunddle insertion.

Craete Axis System with respect to the point which we have created and defining the axis direction as shown below,

Bundle connection point:

Switch to 'Electric Part Design'

Define the part as connector in catia, give no. of termination as 8 because we have 8 entry points for wire.

Define Bundle connection point

Define connector connection point

So like wise we need to define all the connector as electricaly.

Then open the cad file in catia part design workbench and create the connector connection point,connector connection axis system , bundle connection point .Switch to electrical part design and define it as a connector also define connector connection point and bundle connection point.

fig.1. Connector DT06-2S

fig.2. Connector DT06-4S

fig.3. Connector DT06-6S

fig.4. Connector DT06-08SA

All the connectors defined as electrical connector and defined all the necessary properties to Connectors.

create a catalog document in connector family and store all the connector data in catalog document .

fig.4.Catalogdocument

Click on Branch defination

Then click on route defination

select connectors in between we want to create branch.

TO add branch point

select the branch then give ratio or dimension for the point

Final wire harness routing

Now to create protective covering on all branches

switch to electrical harness assembly

select protective covering then select branch - select catalog - select approprite slit cot tubes - give extrimity at start and end - ok

Tree Structure :

Flatten Process :

First of all, we import the week 4 challenge harness bundle to the catia V5

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

STEP1- Defining Harness Flattening parameters

First, we should make a new product file inside the Electrical Harness Flattening workbench. Second, we should define the harness flattening parameters by clicking on its icon as shown above. In the general tab, we should select the settings as shown above. After the general tab settings are complete we should define the settings for the drawing tab as shown below.

It should be noticed that the types of representation for the bundle segment and protective covering are different from each other. Also for devices, "3D projection" can be used if the connectors are added to the electrical drawing catalog.

STEP 2- Rename the product file as the Flattening Product.

STEP 3- Bring the harness assembly into the newly created Flattening Product by using the "Extract" feature.

First, we should align the Flattening Product and Harness Bundle tabs vertically. Now, as shown below, we should use the "EXTRACT" feature in the electrical harness flattening workbench to bring the harness assembly into the Flattening product.

It should be noted that our geometrical bundle assembly or harness assembly file is now changed to an "EHF" file which stands for "Electrical Harness Flattening".

STEP4- Flattening of the harness

To flatten the harness we should select the flatten plane and then select all the branches present in the harness assembly as shown below.

The above image shows the raw flattened view of the wiring harness along the selected XY-Flattening Plane.

STEP5- Rotate the bundle segments

All the bundle segments if needed should be rotated in the desired direction as needed by using the "Rotate" feature in the flattening workbench. It should be noted, that as we have "XY-plane" as the flattening plane so we should make sure that we rotate the bundle segment only along the "XY-plane".

We select the required active plane and select all branches and flatten the wires.

Now we perform the rotation and straightening functions to bring the wire to a standard view using the rotate and straighten tools.

Now create a drawing sheet from the file - new , drawing

select the inputs standard and sheet style then create.

Now select the required view ie front view and select the required view /face from the flattened wire. now the drawing is imported.

Now in order to get the bundle lives visible we adjust the properties by right-clicking on the drawing frame.

Change the dress-up settings and tick 3D colors and 3D Wireframes and the drawing will become visible.

Conclusion :

Flatten the wiring harness assembly in the week 4 challenge with the help of catia v5 in that Electrical Harness Flattening workbench.