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

Route the following harness layout in Electrical workbench

OBJECTIVE:- Flatten the harness assembly completed in “ week 4 challenge”. Place the flattened view on drawing sheet. Ensure bundles with protective coverings has different visuals on drawing view.

Download connector 3D data from www.te.com

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

DESIGN & ROUTING METHODOLOGY

• Download the Connectors 3D data from te.com
• Open the downloaded Connectors in Part Design workbench of Catia and Save as .CATPart
• Open each Connector and Create
  • Connector Connection Point
  • Bundle Entry Point
  • Axis system on Connector Connection Point and Align the Y-Axis in Mating direction & X-Axis in the direction of Lock.
• Open each connector in Electrical Part Design workbench & Define Electrical properties.
  • Click on Define Connector Symbol and then select the part.
  • Click on Define Bundle Connection Point Symbol and fill the opened dialogue box.
  • Click on Define Connector Connection Point Symbol and fill the opened dialogue box.
  • Save the Part as Electrical Part.
• Create one Product file in Assembly design workbench as Wiring Harness Context Assembly
• Create another Product file in Assembly design workbench as Geometric Bundle under Wiring Harness Context Assembly
• Add all connectors under the Geometric Bundle in Assembly design workbench.
• Place all the connectors at desired locations as per given picture using Manipulation, Snap & Smart Move option.
• Now open the Geometric Bundle Assembly in Electrical Harness Assembly workbench.
• Click on Geometrical Bundle Symbol and select Geometric Bundle Assembly to defile Geometric Bundle Assembly as Electrical.
• Now Click on Multi-branchable Symbol and fill the opened dialogue box.
  • Bundle Diameter
  • Bundle Bend Radius ( Ratio must be > 1.4 )
  • Build Mode As slack
• Now Click on Route definition
  • Select DT06-08SA Connector and then DT06-6S connector and click Ok.
  • Now click on Add branch Point Symbol and select the created bundle.
  • Click on length and enter 100 and click ok.
• Now repeat last two steps to complete the given harness routing.
• Now create Electrical harness Flattening file & define Harness Flattening Parameters
• Now click on Extract and select the File to be flatten i.e. Geometric Bundle
• Now click on Flatten to Flat the assembly.
• Now Create Drafting file to create the drawing of flatten Assembly.
• Select the Sheet Size As A0 & Place the view by clicking on Front View option.
• Now save the drawing file.

Harness Assembly Steps

Step-1 Download the Connectors 3D data from www.te.com

Step-2 Open the downloaded Connectors in Part Design workbench of Catia and Save as .CATPart

Step-3 Create one point on mating surface of Connector & rename it to Connector Connection Point.

Step-4 Create one point on Bundle Entry surface of Connector & rename it to Bundle Entry Point.

Step-5 Create Axis system on Connector Connection Point and Align the Y-Axis in Mating direction & X-Axis in the direction of Lock.

Step-6 Now open the Electrical Part Design workbench of Catia & Click on Define Connector Symbol and then select the part.

Step-7 Now click on Define Bundle Connection Point Symbol and fill the opened dialogue box.

In Representation – Select the Green Highlighted Surface

In Point – Select the Bundle Entry Point

In Initial Conditions – Select the Green Highlighted Surface

Step-8 Now click on Define Connector Connection Point Symbol and fill the opened dialogue box.

In Representation – Select the Connector Connection Point

In Contact – Select the Green Highlighted Surface

In Coincidence – Select the Y-Axis

In Orientation – Select the X-Axis

Step-8 Save the Part as Electrical Part.

Step-9 Repeat same Steps for all Connectors & save the as Electrical Part.

Step-10 Create one Product file in Assembly design workbench as Wiring Harness Context Assembly

Step-11 Create another Product file in Assembly design workbench as Geometric Bundle under Wiring Harness Context Assembly

Step-12 Add all connectors under the Geometric Bundle in Assembly design workbench.

Step-13 Place all the connectors at desired locations as per given picture using Manipulation, Snap & Smart Move option.

Step-14 Now open the Geometric Bundle Assembly in Electrical Harness Assembly workbench.

Step-15 Click on Geometrical Bundle Symbol and select Geometric Bundle Assembly to defile Geometric Bundle Assembly as Electrical.

Step-16 Now Click on Multi-branchable Symbol and fill the opened dialogue box.

• Bundle Diameter
• Bundle Bend Radius ( Ratio must be > 1.4 )
• Build Mode As slack

Step-17 Now Click on Route definition

• Select DT06-08SA Connector and then DT06-6S connector and click Ok.
• Now click on Add branch Point Symbol and select the created bundle.
• Click on length and enter 100 and click ok.

Step-18 Now repeat last two steps to complete the given harness routing.

Step-19 Now create Electrical harness Flattening file & define Harness Flattening Parameters

Step-20 Now click on Extract and select the File to be flatten i.e. Geometric Bundle

Step-21 Now click on Flatten to Flat the assembly.

Select the desire plan i.e., Face of Connector

Then select the Geometric_Bundle_Ehf and click ok to flatten the assembly.

Step-22 Now Create Drafting file to create the drawing of flatten Assembly.

Step-23 Select the Sheet Size As A0 & Place the view by clicking on Front View option.

Step-24 Now save the drawing file.