Wiring harness design in CATIA V5 - 3D modeling Week 5 & 6 Challenge

AIM-  Route two electrical harnesses as per the given layout and interconnect them as a single harness assembly and then check for bundle continuity, bundle warnings, and then give annotations to the final harness assembly.

OBJECTIVE-  

1. The objective of this project is to first route the two Harness A and Harness B as per the given harness layout.

Figure 1: Shows the layout of two Harness A and Harness B

The electrical connectors are represented by numbers in the above figure. There are 8 different types of connectors at 10 different locations.

    2. Bundle continuity has to be checked for the two created harness.

    3. After the two Harnesses are created, the next objective is to have them interconnected electrically.

    4. Check for bundle warnings in Harness A and Harness B.

    5. Add annotations to all the connectors in Harness A and Harness B.

    6. The final objective of this project is to convert the final harness file into IGS file format.

CONTENT-

The following steps are to be done to complete this project.

STEP1-Define all the electrical connectors geometrically and electrically so that they can be used in the wiring harness.

STEP2-Create harness A and harness B as shown below by using the electrical harness workbench in CATIA V5.

First, all the connectors are placed at their desired locations. Second, bundle segments are created between the connectors with branch points and branches as shown below. 

Bundle diameter is assumed to be 20mm, 15mm, 10mm, and 5mm for different bundle segments. Bend ratio is given as 1.4 and slack is given as 0% for all the bundle segments.

Harness A:

Harness B :

STEP3- After Harness A and Harness B are created the next step is to check the bundle continuity. 

First, we have to make sure multi-branchable is selected and then we have to go in Edit>Search>Advanced>Electrical Workbench>Type-Bundle Segment>Attribute-Fully Connected.

Selecting the "TRUE" option will show all the connected bundle segments while selecting the "FALSE" option will show all the non-connected bundle-segments.

For now, we will select the "TRUE" option and search for results. All the bundle segments in Harness A and Harness B will be displayed showing that there is bundle continuity in Harness A and Harness B.

STEP4- In this step, we have to interconnect the Wiring Harness A and Harness B electrically. There are a few steps that have to be followed to connect the two harnesses electrically.

First, make a new product file in CATIA and rename it as "FINAL HARNESS ASSEMBLY". Make sure to open the three windows vertically .

Assembly :

CONCLUSION-  Routing of the two electrical harnesses as per the given layout was achieved and interconnection between them as a single harness assembly was established. Both the harness were checked and corrected for bundle warnings and bundle continuity. At the very end, annotations were added to all the connectors and the final harness assembly file was converted into IGS format.