Challenge

Wiring harness routing & packaging Rules Week 3 Challenge

SSaravana Kumar12 Apr 2023

AIM:

To solve the above assignment questions and define the necessary electrical properties in the respective workbench.

INTRODUCTIONS:

wiring harness:

A wire harness, often referred to as a cable harness or wiring assembly, is a systematic and integrated arrangement of cables within an insulated material. The purpose of the assembly is to transmit signal or electrical power. Cables are bound together with straps, cable ties, cable lacing, sleeves, electrical tape, conduit, or a combination thereof. The wire harness simplifies the connection to larger components by integrating the wiring into a single unit for “drop-in” installation. A wiring harness consists of different sets of connectors like terminals and wires which run through the entire vehicle and transmit information.

A wire harness process is designed based on the geometric and electrical requirements of the equipment it is to be installed in. Once the initial design is established, a schematic is used to create the manufacturing paperwork and the assembly board for the harness. The assembly board, also called a pin board, is a full-size diagram of the harness that shows all of the components and their locations. It also serves as the workbench for the harness.

clips:

Clips are ideal elements for retaining / holding pipes, cables, cable harnesses, hoses etc. Clips act as form fitting adjustable bands for ease of assembly & installation. The band ends of the clips are reinforced to prevent any tearing or loosening due to high mechanical loads. ‘P’ clips are fitted with EPDM liners which help achieve a tighter grip on the cable / conduit & also act as dampeners for sound & vibration.

back shells:

A back shell is a mechanical device threaded into the rear of an electrical connector and is designed to provide screening, sealing, and reparability. Engineered to help resist corrosion and fit a wide range of circular connectors, back shell components help protect connections from mechanical wear, environmental conditions, and electromagnetic interference (EMI). These are available with and without screen termination, providing long-term, high performance in sealed and unsealed electronics systems.

corrogated tubes:

Corrugated tubes made from flame-retardant material these tubes will protect cables from impact and abrasion. They are highly flexible and have a high fatigue life, making them ideal for any installation. Depending on the intended use, corrugated tubing is manufactured in different diameters and from different materials. Even though these are usually rigid materials, convoluted plastic tubing becomes flexible and bendable due to its corrugated manufacturing method.

1. P CLAMP INTO ELECTRICAL SUPPORT:

P-Clamp is an Electrical Support equipment which provides support to the wire bundle to remain fixed to the automobile or any components or parts.

The wire bundle can enter and exit from any side as it is a bi-directional equipment.

So, we need to specify the Entry and Exit points from both the sides.

First download the CAD part and open it using the CATIA V5 software.

Now we have to define the geometry parameters. In order to define the geometry parameters, we need to navigate to the Part Workbench.

Then we need to create points and plains at the entry and exit points.

Now in order to define the P-Clamp as a Electrical support we have to navigate to the Electrical Part design Workbench.

Now using the 'Define support part' option we can define the P-Clamp Entry and Exit points.

As the P-Clamp is Bi-directional so we need to define the support two times.

TREE STRUCTURE:

2. BACK SHELL INTO ELECTRICAL PART:

A backshell is an accessory that mounts to the rear threads of a connector to enhance its operational characteristics. The primary function of a backshell is to provide strain relief, which minimizes stress from the cable, on the junction where the wires terminate to the contacts.

Backshells come in a variety of finishes, materials, and angle configurations. For material compatibility and aesthetics, backshells and connectors should have a matching material and finish. And to provide simple cable management, most backshells may be ordered in 45º and 90º angles.

Download the neutral data file (step file / igs file) of the back shell from the given source (TE connectivity website) and open it in the CATIA part workbench.

Study the back shell model and understand the faces of the back shell connection point, bundle connection point and mechanically locking sides.

Create the geometries like center points of back shell connection point, and bundle connection point by selecting appropriate edges and create an axis on the back shell connection point with respect to the same axis direction of the compatible mating part by placing the Y axis towards back shell connection point (mating point) direction and the X axis pointing towards the side of the locking mechanism.

Now switch to the electrical part design workbench and define the model as an electrical back shell part by using the define back shell command. Define the back shell connection point by giving the representation as the back shell connector point, selecting the face of contact, coincidence direction as Y axis and orientation direction as X axis.

By using the define bundle connection point command available in the electrical part design workbench and by selecting the face of the bundle entry side and the created bundle center point define the bundle connection point of the back shell.

Now the back shell part file is converted into the electrical part file with all electrical

TREE STRUCTURE:

3. Create different corrugated tubes as per the given data and add them to a new catalog:

Read and understand the given data file of different types of corrugated tubes by their name, inner diameter, outer diameter and thickness. Then calculate the bend radius of the corrugated tubes with respect to their outer diameter. The bending radius of standard corrugated tubes will be 1.5 times to its outer diameter. By using this method, the bending radius of each corrugated tube is calculated.

First we have to create a new catalog named as “Slit COT” by creating a new file and model as a new catalog document then use add family option available in the popup screen by giving the desired name (Slit COT) and type as conduit save the catalog to the desired location with a proper file name.

Now switch to the electrical part design workbench and go to the define protection part command a pop-up window will appear to select the type as corrugated tube and give the appropriate inner diameter, thickness, bend radius as per the given input data and adjust the line type if required. Always keep a light geometry profile for protective coverings like corrugated tubes and insulation tapes.

After creating the corrugated tube add each file to the saved catalog “Slit COT” using the command store device and by selecting the appropriate catalog and family.

Follow the same steps for creating different types of corrugated tubes and saved them to the catalog so that we can use them for further operations.

15 MM COT: