Wiring harness routing & packaging Rules Week 3 Challenge

WIRING HARNESS ROUTING AND PACKAGING RULES (Clips, Backshells & Corrugated tubes)

Objective

The project aims to comprehensively examine and understand various models of clips, backshells, and corrugated tubes. The primary objective is to convert the CAD data file of the P clamp into an electrical support and transform the Backshell into an electrical backshell. This transformation will be achieved using the Electrical Part Design workbench within the CATIA V5 tool. Additionally, the project involves creating different corrugated tubes according to provided data and organizing them into a new catalog named "Slit COT."

Introduction

Wiring Harness

A wire harness, or wiring assembly, is a methodical arrangement of cables within an insulated material designed to transmit signals or electrical power. It simplifies connections to larger components, integrating wiring into a single unit for efficient installation. The wire harness consists of connectors, terminals, and wires running through the vehicle to transmit essential information.

The wire harness process is tailored to the geometric and electrical requirements of the equipment it is installed in. Schematics are used to create manufacturing paperwork and assembly boards, providing a full-size diagram of the harness components and their locations.

Clips

Clips are crucial elements for retaining and holding various elements such as pipes, cables, cable harnesses, and hoses. They act as adjustable bands, ensuring ease of assembly and installation. 'P' clips, for instance, are equipped with EPDM liners for a tight grip, acting as dampeners for sound and vibration.

Backshells

Backshells are mechanical devices threaded into the rear of an electrical connector, providing screening, sealing, and reparability. They protect connections from wear, environmental conditions, and electromagnetic interference, contributing to long-term, high performance in electronics systems.

Corrugated Tubes

Corrugated tubes, made from flame-retardant material, protect cables from impact and abrasion. They are highly flexible, with a high fatigue life, suitable for various installations. The manufacturing process results in tubes of different diameters and materials, offering flexibility and bendability.

1. P Clamp into Electrical Support

Steps Followed:

1. Study the P-clamp clip model, understanding cable/bundle passage, and identifying entry, exit, base, and mechanically connected faces.
2. Define points and planes for the bidirectional P-clamp, considering entry face, exit face, and base face.
3. Download the P-clamp's neutral data file and open it in CATIA's part workbench.
4. Define center points for entry and exit faces by selecting appropriate edges, creating parallel planes through these points.
5. Create the base plane by offsetting it directly from the base face.
6. Switch to the Electrical Part Design workbench and define the P-clamp model as an electrical support using the 'Define Support Part' command.
7. Repeat the same command for both entry and exit faces, transforming the CAD part model into an electrical support model.

8. 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 Electrical Back Shell

9. Steps Followed:

   1. Download the Neutral Data File: Download the neutral data file (STEP file / IGS file) of the back shell from the provided source (TE Connectivity website) and open it in the CATIA part workbench.

   2. Study Back Shell Model: Examine the back shell model to understand the faces of the back shell connection point, bundle connection point, and mechanically locking sides.

   3. Create Geometries: Create the necessary geometries, such as center points of the back shell connection point and bundle connection point. Generate an axis on the back shell connection point, aligning it with the same axis direction as the compatible mating part. Orient the Y axis towards the back shell connection point (mating point) direction, and the X axis towards the side of the locking mechanism.

   4. Switch to Electrical Part Design Workbench: Transition to the Electrical Part Design workbench.

   5. Define Model as Electrical Back Shell: Use the 'Define Back Shell' command to categorize the model as an electrical back shell part. This step ensures that the software recognizes and processes the model with electrical properties.

   6. Define Back Shell Connection Point: Define the back shell connection point using the following parameters:

      • Representation: Set the representation as the back shell connector point.
      • Face of Contact: Select the appropriate face of contact on the back shell.
      • Coincidence Direction: Choose the Y-axis as the coincidence direction, aligning it with the desired direction towards the back shell connection point.
      • Orientation Direction: Select the X-axis as the orientation direction, aligning it with the side of the locking mechanism.

   7. Define Bundle Connection Point: Use the 'Define Bundle Connection Point' command available in the Electrical Part Design workbench. Select the face of the bundle entry side and the previously created bundle center point to define the bundle connection point of the back shell.

   8. Conversion to Electrical Part File: The back shell part file is now successfully converted into an electrical part file, incorporating all necessary electrical properties. This ensures that the back shell can be seamlessly integrated into the electrical system, meeting design and assembly requirements.

   9. 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.

   10. 3. Create Different Corrugated Tubes and Add to New Catalog

       Steps Followed:

       1. Read and Understand Given Data: Review and comprehend the given data file containing information on different types of corrugated tubes, including their names, inner diameter, outer diameter, and thickness. Calculate the bend radius of each corrugated tube based on its outer diameter, using the standard formula of 1.5 times the outer diameter.

       2. Create New Catalog (Slit COT):

          • Open a new file and model it as a new catalog document.
          • Use the "Add Family" option in the popup screen, naming it "Slit COT" and specifying the type as conduit.
          • Save the catalog to the desired location with an appropriate file name.

       3. Switch to Electrical Part Design Workbench:

          • Transition to the Electrical Part Design workbench.

       4. Define Protection Part (Corrugated Tube):

          • Use the "Define Protection Part" command.
          • In the popup window, select the type as corrugated tube.
          • Input the appropriate inner diameter, thickness, and bend radius as per the given data.
          • Adjust the line type if necessary, ensuring a light geometry profile suitable for protective coverings like corrugated tubes.

       5. Add to Catalog "Slit COT":

          • After creating each corrugated tube, add the file to the saved catalog "Slit COT" using the "Store Device" command.
          • Select the appropriate catalog and family for each corrugated tube.

       6. Repeat for Different Types:

          • Follow the same steps for creating different types of corrugated tubes, adjusting parameters as needed.
          • Save each corrugated tube to the catalog "Slit COT" to build a comprehensive library.

       By following these steps, you establish a catalog named "Slit COT" containing various types of corrugated tubes, each customized based on the provided data. This organized catalog can then be utilized for future operations in the design and assembly of wiring harnesses, ensuring flexibility and efficiency in the process.

   11. 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.

   13. Saved corrugated tube files to 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.

   14. conclusion:- the project successfully achieved its objectives by applying a systematic approach to convert CAD part models into electrical support models and create various components such as electrical back shells and corrugated tubes. The specific focus on the P-clamp, back shell, and corrugated tubes showcased a comprehensive understanding of the methods employed in the CATIA V5 tool.

       The conversion of the P-clamp into an electrical support model involved a meticulous study of the clip model, identifying key features, and executing precise commands in the Electrical Part Design workbench. Similarly, the transformation of the back shell into an electrical back shell required careful consideration of the back shell model's faces and connection points.

       Furthermore, the creation of different corrugated tubes demonstrated proficiency in interpreting given data, calculating bend radii, and organizing them into a new catalog named "Slit COT." The steps outlined in the project showcased a clear methodology, from creating a new catalog to defining protection parts and cataloging various types of corrugated tubes.

       Overall, this project enhanced understanding of CAD-to-electrical conversion, catalog creation, and adherence to wiring harness routing and packaging rules. The acquired skills and methodologies are crucial in ensuring the efficiency and precision of the design and assembly processes in the realm of electrical systems.