Wiring harness design in CATIA V5 - 3D modeling Week 7 Challenge
PREPARE THE MECHANICAL CONNECTORS TO ELECTRICALY:
Download the connectors from TE.COM.Open the website enter Connectors Model Number in Search Button, and open the connectors Select and download the CAD Zip file.Finally open the cad file by using CATIA Sostware Identify the connecter connectivity and bundle connectivity in Part workbench.Then we have been creat the point and axis in mounting direction by using part work bench.like y axis direction is coinsidence ,x axis is orientation and z axis is side facing.
After this process we have been pick on define connector option .The define connector window is open Enter the type - single insert connector , Number of terminitions and click ok. next pick on connector connectivity point and give require detailes like , representing point - Point , Contact - Face , y - direction - coinsidence , X - direction is oriendation and click ok , at same time we have been open on Bundle connection point give the representation side - face , point , Initial condition - face and say ok.
CATAOLOGUE DOCUMENT CREATION:
Then part will be add on storage device .if you add family first we want catalogue document.so create the catalogue document by using File - new - click catalogue document option open the window click on Add family option open on small window . thwe window ask for name - CONNECTOR and select which type we want to save ex : ELECTRICAL , then say ok. next pick add part familly option open window default name and type -ELECTRICALthen say ok .
finally open the electrical part design work bench select device storage tool click on add familly go to folder location ,pick on catalogue document file and say ok.next come to storage device window select family CONNECTOR and say ok the part will have been saved on catalogue document.
CARROUGHTED TUBE CREATION :
corrugated tube creation is doing on electrical part design workbench first open on new part workbench then change to electrical part design workbench then go to click define protection part option and click part body on Geometry tree structure .
The option will be open and give required values like : Name ,Type - Corrugated tube , Inner diameter - 12mm ,Inner section is Creat automaticaly depensupon the inner diameter values ,Thickness - 1.5mm,Bend radius - 25mm ,Linear mass - 0.1 kg and line type - straight line symbol and say ok.The covering tube would be creat and then go to save.
Next the part will be add on storage device .if you add family first we want catalogue document.so create the catalogue document by using File - new - click catalogue document option the catalogue window open and give name and select which type we want to save ex : conduit , then say ok. next pick add part familly option open window default name and select which type of part then say ok .
finally open the electrical part design work bench select device storage tool click on add familly go to folder location pick on catalogue document file and say ok. then come to storage device select familly and say ok .the part have been saved on catalogue document.
CATAOLOGUE DOCUMENT CREATION FOR CARROUGHTED TUBE:
Next the part will be add on storage device .if you add family first we want catalogue document.so create the catalogue document by using File - new - click catalogue document option open the window click on Add family option open on small window . the window ask for name - SLIT_COT and select which type we want to save ex : conduit , then say ok. next pick add part familly option open window default name and type -Conduit then say ok .
finally open the electrical part design work bench select device storage tool click on add familly go to folder location ,pick on catalogue document file and say ok.next come to storage device window select family SLIT_COT and say ok the part will have been saved on catalogue document.
How to Assemble and Routing the wiring harness :
Next we have decide the Assemble and routing the cable for the all connectors .So open the Product file and change the assembly design work bench ,give the name of Week 7_Wiring_Harness_Assembly,then creat suproduct by using right click component option, name of Assemble_Wiring_Harness.
So start the Assemble process go to pick on Assemble_Wiring_Harness option select new component option go to the location select and open on all required connectors also.then Assemble for the all connectors by using assemble option like ,ex ( manupulation,rotation,snap & compas command ).
The assemble area ,length and dimension are as per layout.when will complete the assemble then start for routing process.First change the electrical Harness assembley workbench and ensure thet you have your harness geometrical bundle is highlighted. select icon on electrical Harness assembley and pick on product .next we have select the Muiti branch document icon open the branch definition window box input all required values like :name : Branchable .1 , Daimeter : 15 mm (this is main trunk branch routing diameter )and We have additional 4 branches are routing in this challange.they are 10mm Dia & 5mm Dia.Section: 1:13Ie-004m2 (its automatically created),Bend radius : 14mm,Bend radius ratio : 1.4 and mode :slack
After the input values click on Routing Definition Option Select one end connector Bundle connectivity point side and change or ensure bundle direction by using reverse tangent option and ensure the Add After the option are highlighted , select the Connector-4 Bundle side the cable have routed successfully ,full main trunk routing is completed and add branch point option .select this option open on the window select refernce point give lingth valve from referance point say ok the brance point will be created. our branch point length was : 100mm length ,150mm,250mm like this .then same process is doing on the create branch routing.
Finally Carrougted tube is most importent think on the cable routing process.complete the wiring harness exit the multi branch option pick on define protection option in before select rougting cable .After the click the option the cataloge document window will be open and select which type of size we want and say the corrugated tube have applyed on the roughting cable.We have choose for Size : 20mm , 10mm, 15mm Like that .
FLATTENING:
Open the new product and change the work bench in Electrical Harness Flattening,Before entry the flattening Workbench we have change some settings,they are Start - Electrical & Equipment - Electrical Harness Decipline - Electrical Wiring harness Flattening open the window click new formOption and say ok.Then go to the Assembly Work bench Change the settings ,they are TOOLS- OPTION-Open the Harness Flattening Parameter window - click Genreal and pick the required option and say ok then save .
open the the flattening workbench select the wiring_Harness Flattening Parameter option and select the required parameters like:For bundle segment - Single line ,For Device - 2D Detailes and say ok the commend will join the geometrical tree structure.next pick on page option and select the wiring harness assembly the assembly will copy and past the flattening work bench and click the update .then we have choose the flattening option,select the connector face and select the all branches and say ok then the Wiring harness assembly would be flattening.Next we have choose the rotation command and select the wiring branch give angle and ok the branch would be changed.the process doing on roll command select the roll command pick the required wiring routing branch and click on some little distance .after clicking the distance the branch will be roll on respected to distance point.The scaling option is also doing in the flattening click the scale command and pick on some one routing branch and give the length value and ok the wiring harness routing length would be modified.Finally we have doing on Synchronize.sychronize is if any protection covering fix on wiring Harness assembly at same time we want flattening Assembly also covered.Select the sychronize option and show the window then all option are there in the window if we have dont change on the option and say ok.Finally the Carroughted tube also covered in the Flattening Assembly.
DRAWING OF FLATTENING :
Drawing Work bench is open when i Click the File - new - Drawing,then the drawing work bench will be open. before some setting will be change like :For bundle segment - Single line ,For Device - 3D Projection and say ok.Now pick front view option and select the Assembly wiring Harness Work bench and pick on drawing workbench only the component have visiable the routing did not visiable.so right click - properties- open the window - pick view Select Always 3d wireframe and select is always visiable then the wiring harness routing also visiable. next we have go to pick the dimension tools and create the wiring harness branch cutting length dimensions ,branch rotation angle etc.If we want to change color for connector and carroughted tube select and others select the color option and change .
Next we have prepare the table for Title Block ,BOM (Bill of Material) ,Wire Cut List ,Connector List,Connector View for Drawing A0 lAYOUT.Like Title Block location is right side bottom,BOM is right side ,Wire cut List - right side Top ,Connector List is Top center, Notes - Left side bottom.