Wiring harness routing & packaging Rules Week 3 Challenge

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

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 . 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.

challenge:

Aim:

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

Objective:

1. Download the following cad data & define it as Electrical support using Electrical Part Design Workbench. Define all the necessary properties.

2. Download the following Back shell cad data & define it as an Electrical back shell using Electrical Part Design Workbench. Define all the necessary properties.

3. Create the Following Corrugated tubes & Add them to the Catalogue under the “Slit COT” family.

Design Methodology:

1. P-Clamp:

1) Create two points one as entry and another as exit point.

2) create planes at two points and another at base.

3) Switch to Electric part desgn

4) Click on support definition - select part - select entry point - select entry plane, exit and base plane.

5) Again Click on support defination - select part - select exit point - select exit plane and base plane as secondary plane is automatically taken.

2. Backshell:

1) create Back shell entry point.

2) create axis system for back shell entry.

3) create bundle connection point.

4) witch to Electrical part design.

5) Define part electricaly as back shell.

6) Then define Back shell connection point.

7) Define bundle connection point.

COT Tubes Creation:

Catalogue under “Slit COT” family.

Name	ID (mm)	OD (mm)	Thickness (mm)
15mm COT	12	15	1.5
20mm COT	17	20	1.5
35mm COT	32	35	1.5
10mm COT	7	10	1.5
5mm COT	3	5	1

Process:

1) First, we create a new part.

2) Switch to Electrical Part Design.

3) Select the define protection part.

4) Click on part ( on the file name in specification tree)

5) Provide given parameters and bend radius as '1.5*Outer Dia'

Catalogue Cretation:

1) First, we create a new part in the Catalog document.

2) Add family rename as Slit COT and select the type as Conduit then the save file.

3) Open part to add Catalog.

4) Select the store device command and select Catalog and select family as Slit _COT then click on ok.

(all catalogue fill stored the same catalogue file its east to retain and easy to update the corrugated tubes.)

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.

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.