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

AIM: Q1. 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.

Electrical connector: An electrical connector is a device or mechanism used to establish a physical and electrical connection between two or more electrical circuits or components. Connectors enable the transfer of electrical signals, power, or data between different devices or systems. They come in various shapes, sizes, and configurations to accommodate different requirements, such as the number of pins or terminals, the type of signal being transferred (analog or digital), the environment in which they will be used (indoor, outdoor, harsh conditions), and more. 

Electrical connectors typically consist of two main parts: 

• Plug: This is the male component of the connector, usually having protruding pins, prongs, or sockets that match with corresponding receptacles in the female component. 
• Receptacle: This is the female component of the connector, designed to accept the plug and create a secure electrical connection with its pins, prongs, or sockets. 

Wire: Wires are essential components of wire harnesses, which are organized assemblies of multiple wires, cables, or conductors that are bound together in a specific arrangement and encased in a protective covering. Wire harnesses are used to transmit electrical signals or power between various components, devices, or systems within a larger structure, such as an automobile, aircraft, industrial machinery, or electronic equipment. 

Protective Covering: The protective covering in a wire harness serves as a barrier that shields the individual wires and cables within the harness from various environmental factors and mechanical stresses. This covering not only provides physical protection but also contributes to the overall organization, durability, and reliability of the wire harness. There are different types of protective coverings used in wire harnesses, each designed to address specific requirements and conditions. 

Ex: Heat Shrink Tubing, Conduit, Tape, Loom, Cable Tie, Spiral Wrap, Connector Boots, Grommets, Heat-resistant Sleeving. 

Below Steps need to be followed to create the Wire Harness 

    1. Download Connector 3D:

• Download CAD data from manufacturers' or distributors' official websites.  

Create Required Geometrical Parameters:

• Create Connection Point using the Part Workbench for Back Shell. 
• Create the axis using point as reference using the Part Workbench. 
• Create Bundle Connection Point using the Part Workbench. 

    2. Create Required Protective Coverings:

• Create the protective coverings using the “Define Protection Part” 
• Define, Name, Type of protection part. 
• If the protection part is Corrugated tube, define Inner Dia, thickness and bent radius. 
• If the protection part is Tape, define Width, thickness and bent radius. 
• Store them in the catalog to use it multiple times. 

    3. Create Assembly file:

• Create the Assembly file and import all the connectors and position them as shown in the figure or requirement. 
• Go to Electrical Harness Assembly workbench and use “Geometrical Bundle” option to convert the Part Assembly file to Electrical Part Assembly file or bundle. 
• Use “Multi-Blanchable Document” and “Add Local Slack” option to create the branch between connectors. 
• Use “Protective Covering” option and add the necessary protective covering using the catalog, where coverings are created and stored. 

     4. Create Assembly File with Flattening Parameters:

• Create the Assembly file and using the Electrical Harness Flattening to create the Flattening Parameters using the option "Harness Flattening Parameters".
• After creating the Flattening Parameters using the option "Extract" Extract the assembly to the created Assembly file.
• Next by using the appropriate the option create the flattned harness assembly.

     5. Drawing

Conclusion: The flattened view is shown on the drawing sheet. The bundles with protective coverings has different visuals on drawing view.