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

WIRING HARNESS FLATTENING TECHNIQUES

AIM:

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

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

To flatten the completed harness assembly. 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

PROCEDURE:

Download the Parts from www.te.com.

· DT06-4S

· DT06-6S

· DT06-2S

· DT06-08SA

Go to website > Search > Type Component name > Select the file type iges or stp > Download > Open in Catia V5.

1.CONNECTOR DEFINITION:

· Following Parameters are required to defined for any connector -

· Geometry Parameters - Points & Co-ordinate system (Axis)

· Connector connection points - This point is used for the connection of one connector to another connector.

· Harness bundle entry point - This point defines where the harness bundle segment point will end when routed to the electrical connector.

· Cavity connection point (Optional) - This point is used to define the connection of a connector to a connector clip. This only applies to connectors which have the mounting feature for a connector clip.

DT06-2S

DT06-4S

DT06-6S

DT06-08SA

2. PRODUCT CREATION & PART POSITIONING:

· After given the electrical properties to all the connectors then start the Preparation of Harness Assembly.

· Create a master product file (WIRING_HARNESS_ASSY(BUNDLE)) and create a sub-level product file named (ASSY_GEOMETRY_BUNDLE) and save it.

· Once Geometrical Bundle is created, then open it in a new window. Select the "Geometrical Bundle" command and then click on Product (ASSY_GEOMETRY_BUNDLE) Icon in Model tree to convert it in to an Electrical Assembly.

· Inserting Harness Connector Components into the Geometrical Bundle. Before Inserting the components, ensure that all the required components have been electrically defined.

· Once the required components were defined electrically, then insert them using Catalogue Browser command or using existing component command.

· After inserted all component position them it according to the reference diagram. Before start routing, ensure all the components in its desired location according to surrounding data.

· If not then place and position the components by using any of the following commands like Manipulation, Translation or Rotation, Snap, Smart Move, Compass.

· In our case we created a reference sketch according to the given input and fixed components to the created reference sketch.

· If there are any assembly that need to be assembled before routing like Connector with Mounting Clip or Connector with back shell. Then Assemble them using "Connect Electrical" Devices.

3. BRANCH CREATION:

· Switch to Electrical harness Assembly Workbench.

· Select Multi-Branchable Document Icon.

· In the Branch Definition Box (Ref Below Image), give all the required parameters like Diameter, Bend Radius (>1.4), Build mode (slack, Length, Bend, Straight Bend).

· Click Route Definition and select the two components that you need to route.

· Click OK.

· Once the multi-branchable is created, Click Add branch point command and define the point on the main branch where the Harness Branch needs to be created.

· After creating the point repeat the steps of multi-branchable creation.

4. ADDING PROTECTIVE COVERING :

Add protective covering on the required branches by using Protective Covering Command and mention the start and end extremity points.

Switch to Electrical Harness Assembly > Select the Protective Covering > Select the Bundle Segment > Select the size of protective covering > Give its end extremity > Click OK

5. FLATTENING OF HARNESS ASSEMBLY:

· In order to flatten the Assembly, we have to define the Flattening Parameters in “Electrical Harness Flattening Workbench”

· We have to define the desired plane that we want to work on and Select the desired parameters according to your requirements.

· We have to ensure that the bundle segment, protective covering and devices representation should be different from each other just for recognizing purpose. For that we have to enable parameters like the below image.

· Now, we have to bring Harness Assembly into newly created Flattening Product by using Extract command in 'Electrical Harness Flattening' workbench. Here, we have to tile both the files (Flattening Product file & Harness Assembly source file) vertically.

· Now, we have to flatten the given Harness Assembly and for that we have to choose plane or face of the connector after that select all branches of the Harness Assembly.

· Now, we have to use rotate, scale, Roll, Bend etc to make it look representable. After that our resultant flatten file will look like below image.

6. PLACE THE FLATTENED VIEW ON DRAWING SHEET:

· Here, we have to create new drawing (File->New->Drawing) and provide the desired sheet parameters.

· Then import the flatten file into drawing file by using 'Front View' command.

· As shown in above image, the flattened file has been imported and oriented in our desired manner.

· Now, click anywhere on screen of drawing file. At this point we'll have reached below stage.

· Now, we have to provide properties to drawing file. In order to make the connection visible between the connectors like below image.

· Now, we have successfully placed the flattened view on drawing sheet.

· To ensure bundles with protective coverings has different visuals on drawing view

· As you can see above image, the bundle segment is represented in 'Single line' and the protection covering is represented in 'Double line'

· If you want to change the representation then we have to modify the flattening parameters accordingly.

RESULT:

Thus, all our objectives have been successfully completed.