Wiring harness routing & packaging Rules Week 3 Challenge

Aim

The aim of the project is to study and understand the different models of the clips, back shell and corrugated tube and convert the given cad data file of the P clamp into electrical support and Backshell into the electrical back shell by electrical Part design workbench available in the CATIA V5 tool. Then create different corrugated tubes as per the given data and add them to a new catalog named “Slit COT”.

Introduction

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.

Corrugated 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

Steps followed

• Study the P-clamp clip model and understand how the cable / bundle is passed through it and identify the entry, exit, base and mechanically connected faces.
• P-clamp is a bidirectional clamp and we have to define the points and planes along three parameters, entry face, exit face and base face.
• Download the neutral data file (step file / igs file) of the p clamp from the given source and open it in the CATIA part workbench.
• Define the center points of entry and exit faces by selecting the appropriate edges and create the planes which is parallel through the points.
• We can create the base plane by directly offsetting it from the base face.
• Now switch to the electrical part design workbench and define the P-clamp model as an electrical support by using the define support part command.
• Repeat the same command for both entry/exit faces and by applying this the cad part model is converted into an electrical support model.

INPUT DATA

Create the center points of entry and exit faces by selecting the appropriate edges and the planes which is parallel through the points and the base plane by directly offsetting it from the base face.

 

Converting the P-clamp model as an electrical support by using the define support part command and giving appropriate selection on entry/ exit faces. 

 

Repeat the same command for other side of entry/exit faces of the P-clamp

 

 Final electrical support P-clamp

2) Back shell into the electrical back shell

Steps followed

• 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 properties.

INPUT DATA

 

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 properties.

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.

New catalog named as “Slit COT” by created by giving desired name (Slit COT) and type as conduit

In 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.

Conclusion

The cad part model the of P-clamp is converted into the electrical support model, back shell into the electrical back shell and create different corrugated tubes as per the given data and add them to a new catalog thereby understand the methods follow to create and convert the catalog, corrugated tubes, clips, back shells, and wiring harness routing and packaging rules.