WIRING HARNESS FLATTENING & DRAWING WORKBENCH

OBJECTIVE: Take the harness assembly from the previously completed challenge and flatten it. Position this flattened view on the drawing sheet. It’s important to make sure that bundles with protective coverings are visually distinct in the drawing view. This step is part of our ongoing process to create a drawing representation using a wiring harness flattening workbench.

 

PREVIOUS PROJECT'S LINK: https://skill-lync.com/student-projects/wiring-harness-routing-using-provided-layout-applying-suitable-protective-coverings

 

 

CONNECTORS USED IN OUR LAYOUT:

1. DT06-4S: https://www.te.com/usa-en/product-DT06-4S.html

2. DT06-2S: https://www.te.com/usa-en/product-DT06-2S.html

3. DT06-6S: https://www.te.com/usa-en/product-DT06-6S.html

4. DT06-08SA: https://www.te.com/usa-en/product-DT06-08SA.html

 

 

 

Step-by-step instructions on how to flatten our previously created wiring harness layout using the wiring harness flattening workbench:

1. Firstly. We'll open our previously created wiring harness's CATProduct file in CATIA V5. Next, we're going to check the status of the bundle continuity. To do so, we're going to click on the 'Edit' button and then proceed to click on the 'Search' button, as shown below:

After that, the 'Search' dialogue box will open. Next, we'll click on the 'Advanced' button. Under the advanced menu, we'll set the 'Workbench' as 'Electrical', Next, we'll set the 'Type' and 'Bundle Segment', and finally, under 'Attribute', we'll select the 'fully connected' option. 

When prompted with the "Attribute Criterion" dialog box, two options arise:

A. Verify all bundles are connected: Choose "true" to confirm that every bundle within the harness maintains complete electrical continuity. This provides quick validation that no open circuits exist.

B. Identify disconnected bundles: Select "false" to reveal individual bundles lacking continuity. Click "Search" to reveal these specific bundles within the harness. This option helps pinpoint troubleshooting areas.

We're going to go with the 'false' option first to check if there are any discontinuities in our harness layout that were previously created to make sure everything is in the right condition to proceed with the flattening process. 

After clicking on the ' search option, we'll see the results as shown below:

We can see from the above image that CATIA found no objects that are disconnected from our harness bundle. 

We'll repeat these steps and select the 'True' option to see how many of our bundles are in continuity.  

Now, we can see in the above image that all of our bundle segments stored under the 'Multi-Branchable' options are in continuity, and hence we can now proceed towards the flattening operation. 

 

2. We're going to create a new 'Product' file in CATIA and navigate our way into the 'Electrical Harness Flattening Workbench'. Then, we're going to save that product file at the location where our wiring harness is present, following the proper norm. 

 

3. Next, we're going to click on the 'Harness Flattening Parameters' icon and state all of the required parameters that are needed to flatten our wiring harness assembly.

 

When we click on that icon, the Harness Flattening Parameter's dialogue box will open up, as shown below:

 

A) First, the "General" tab lets you customize the flattening parameter names, but the default settings usually suffice. Choose "xy" as the active plane for flattening your wiring harness assembly. If you need to adjust the plane later, click on the "xy plane" option and pick any connector surface or plane suitable for flattening. 

Next, we come across two more options Algorithm Mode and Angular Mode that play different roles in defining your wiring harness flattening parameters:

 

Algorithm Mode:

Fine: This mode uses a more complex and computationally intensive algorithm to achieve a more accurate and detailed representation of the flattened harness. It takes into account the curvature of wires, bends, and other features, resulting in a smoother and more realistic representation. However, it may take longer to process and generate the flattened model.

Coarse: This mode uses a simpler and faster algorithm, sacrificing some detail for speed. It straightens wires more aggressively and may not capture all the intricacies of the harness geometry. However, it's more efficient, especially for complex harnesses where a high level of detail isn't essential.

 

Angular Mode:

Regular: This mode calculates angles between wires and other elements based on their original 3D geometry. This can be useful for maintaining specific angles required for functionality or clearance.

Standard: This mode uses predefined standard angles (e.g., 45°, 90°) for wire bends and intersections. This simplifies the flattened model and may be suitable for less complex harnesses where specific angles aren't crucial.

 

Choosing the right combination of these options depends on our specific needs.

For high-precision applications or detailed drawings, we can use the 'Fine' algorithm in regular angular mode.

For quick visualizations or less critical applications, we can use the 'Coarse' algorithm in standard angular mode.

Balance between accuracy and speed: Experiment with different combinations to find the optimal setting for your project.

We're going to choose 'Coarse' under the 'Algorithm Mode' since we need a simpler and faster output, whereas a complex and computationally intensive algorithm will only result in slowing down the process. 

And, under the 'Angular Mode', we're going to choose the regular mode since opting for "Regular" mode in the Wiring Harness Flattening workbench ensures accuracy and preserves functionality. Unlike "Standard", it avoids introducing unintended bends and faithfully replicates the original harness's angles, crucial for complex designs or where angles impact functionality. While potentially requiring more user input or processing time, "Regular" mode delivers a precise and reliable flattened representation, essential for critical applications.

 

B) Minimum angle between two branches: Setting the minimum angle between two branches in our wiring harness flattening parameters is crucial for achieving a practical and functional design. Here's how the value affects the outcome:

HIGHER MINIMUM ANGLE (e.g., 20 degrees or above):

Pros:

• Creates a less cluttered and easier-to-manufacture harness layout.
• Minimizes sharp bends, reduces stress on wires, and improves reliability.
• Provides more space for component placement and wire routing within the flattened harness.

Cons:

• May require more material due to increased wire length.
• Might not be suitable for very compact applications where space is limited.

 

LOWER MINIMUM ANGLE (e.g., less than 20 degrees):

Pros:

• It can potentially use less material by allowing tighter bends and shorter wire lengths.
• It might be necessary to fit the harness into tight spaces.

Cons:

• Increases the risk of wire damage due to sharp bends and stress concentrations.
• Can make the harness layout more complex and difficult to manufacture.
• This may lead to interference issues between components due to proximity.

 

Ultimately, the ideal minimum angle depends on your specific application and priorities. Consider factors like:

Functionality: Does the application require specific angles for performance or clearance?

Space constraints: Is there limited space for the harness to occupy?

Manufacturing feasibility: Can the harness be easily assembled with the chosen angles?

Reliability: Are sharp bends acceptable from a stress and durability standpoint?

By carefully evaluating these factors, we can choose the minimum angle that balances functionality, space efficiency, and manufacturability in your wiring harness design, and we're going to choose `22^o` as our minimum angle between two branches for the reasons stated above, as it will be more advantageous for us to go with that degree.

 

C) Next, we'll come across options to enable or disable two more options under the general tab. One of them asks if we want to keep the existing tangent between the bundle segment and connector during the flattening step, and the other option asks if we want to extract only the supports inside the geometrical bundle.

Here's an explanation for both of them to understand why these options matter:

i) "Keep the existing tangent between the bundle segment and connector during the flattening step":

WHAT IT DOES: This option preserves the original angle between the wire bundle segment and its connected component (connector, pin, etc.) during the flattening process.

 

WHY YOU MIGHT ENABLE IT:

• MAINTAINING ORIENTATION: Enabling this option ensures the connector remains properly oriented relative to the flattened bundle. This is crucial for maintaining correct functionality and avoiding clashes during installation.
• PRESERVING DESIGN INTENT: If the original design intentionally angles the connector for aesthetic or ergonomic reasons, keeping the tangent helps retain that design intent.

 

WHEN TO DISABLE:

• IMPROVED FLATTENING: In some cases, disabling this option may allow for a more efficient or visually clearer flattening due to increased flexibility in wire placement.
• MINOR ANGLE CHANGES: If the original angle is not critical for functionality or aesthetics, disabling the option might not create significant issues.

 

ii) "Extract only the supports inside the geometrical bundle":

WHAT IT DOES: This option limits the extracted support elements during flattening to only those physically located within the wire bundle geometry.

 

WHY YOU MIGHT ENABLE IT:

• REDUCED DATA: Limiting extracted supports simplifies the flattened representation, avoiding clutter and making it easier to analyze and edit.
• FOCUS ON HARNESS: With only relevant supports, the focus remains on the wiring harness itself, improving clarity and reducing confusion.

 

WHEN TO DISABLE:

• EXTERNAL SUPPORT INTERACTION: If certain external supports interact with the bundle during installation, extracting them is necessary for accurate representation.
• COMPLETE PICTURE: For comprehensive documentation or troubleshooting, extracting all supports might be helpful to understand the full support scenario.

 

Based on our specific design requirements and the desire for a clear representation of the harness in the flattened view, we've chosen to:

• Enabled: "Keep the existing tangent between the bundle segment and connector during the flattening step." This ensures accurate connector orientation relative to the flattened harness, maintaining functionality and design intent.
• Disabled: "Extract only the supports inside the geometrical bundle." As our design doesn't involve any supports interacting with the harness, including all supports would unnecessarily clutter the representation.

 

Finally, it also asks us about our 'Roll Radius' preference for 'Quick Roll', where there are two options to choose from, one of which is 'Radius of Bundle Segment' and the other alternative is 'Bend Radius of the Bundle Segment'.

 

i) RADIUS OF BUNDLE SEGMENT:

WHAT IT DOES: This option uses the actual diameter of the wire bundle segment itself as the rolling radius during the quick roll operation.

Advantages:

• Accurate representation: matches the actual bendability of the wire due to its realistic radius.
• Uniform appearance: Consistent roll applies to all segments regardless of individual bend radius values.

Disadvantages:

• May not match design intent: If individual wires within the bundle have different bend radii, this option might not reflect their specific flexibility.
• Potentially unrealistic rolls: Large bundle diameters could lead to unrealistic tight bends, depending on the overall geometry.

 

ii) Bend Radius of the Bundle Segment:

WHAT IT DOES: This option utilizes the individually defined bend radius values assigned to each segment within the bundle for quick roll operation.

Advantages:

• Design-compliant representation: accurately reflects the intended flexibility of each wire segment based on assigned bend radii.
• More realistic bends: Can accommodate different bend requirements for individual wires within the bundle.

Disadvantages:

• Potentially uneven appearance: Roll radius might vary across the flattened bundle due to differing segment radii.
• Requires prior bend radius definition: Individual bend radii need to be assigned to each segment beforehand.

 

CHOOSING THE RIGHT OPTION:

Ultimately, the best choice depends on your specific design goals and the level of detail you require in the flattened representation.

Use "Radius of Bundle Segment" if:

• You prioritize a uniform and consistent roll across the entire bundle.
• You don't require individual bend radius representations for different wires.

Use "Bend Radius of the Bundle Segment" if:

• You need a representation that adheres to individual wire bend radius specifications.
• You have already defined specific bend radii for each segment.

 

Remember, you can always modify the quick roll radius later as needed, or use the detailed roll tool for more granular control over individual segment bends.

 

D) Next, we're going to keep the 'Flattening Orientation', 'Flattening Scaling', 'Synchronization', and 'Link' settings as default and move under the 'Drawing Tab'.

 

Under the "Drawing" tab, the "Type of representation" option dictates how bundle segments and protective coverings are visually depicted in the flattened view. Understanding the choices and their impact can enhance our documentation and communication.

 

BUNDLE SEGMENT REPRESENTATION:

Single Line: This represents the bundle segment as a single, solid line.

Double Line: This depicts the bundle segment with two parallel lines, creating a "tube" effect.

Our Choice: Choosing a single line for bundle segments is a reasonable and common approach. It offers several advantages:

Clarity: A single line provides a clean and uncluttered representation, particularly for simple harness designs.

Focus on Connectivity: This emphasizes the path and connections of the wires, which is often the primary concern in flattened views.

Efficiency: It consumes less graphical space, resulting in a visually concise representation.

 

However, consider these scenarios where double lines might be beneficial:

Complex Bundles: For densely packed harnesses or bundled cables with different sizes, double lines can offer a better visual distinction between individual wires within the segment.

Multi-layer Structure: If the bundle has internal layers or specific routing requirements within the segment, double lines can depict this information more effectively.

 

PROTECTIVE COVERING REPRESENTATION:

Single Line: This portrays the covering as a single line alongside the bundle segment.

Double Line: This depicts the covering as a "tube" surrounding the bundle segment, similar to the double line option for the bundle itself.

Our Choice: Opting for double lines for protective coverings is a well-considered decision. Here's why:

Clarity and Distinction: It visually separates the covering from the bundle itself, improving clarity and readability.

Emphasis on Protection: This highlights the presence and location of protective elements, which is crucial for design clarity and manufacturing considerations.

Customization: You can assign different colours or textures to the double lines for various coverings, further enhancing identification and understanding.

The ideal representation depends on our specific design, the level of detail required, and the target audience. Consider the trade-offs between clarity, information density, and visual aesthetics when making our choice.

By thoughtfully selecting these options, we can create flattened views that effectively communicate the design intent, functionality, and protection needs of our wiring harness.

 

E) Graphic Replacement Tab 

The "Graphic Replacement" tab in the "Drawing" section allows us to customize how specific elements appear in the flattened representation. Here's a breakdown of each option and your chosen settings:

 

i) For Device:

3D Projection: Displays a simplified 3D projection of the connected device in a flattened view.

2D Detail: Represents the device using a pre-defined 2D symbol or detail drawing instead of the full 3D projection.

Our Choice: Choosing 3D projection for devices is a well-balanced approach. It offers several advantages:

Visual Context: Provides a basic 3D representation of the device, aiding in understanding its location and relationship with the harness.

Space Efficiency: Compared to full 3D models, projections are less graphically demanding, ensuring clear visibility without cluttering the drawing.

Focus on Harness: Maintains the priority of representing the wiring harness itself while still providing device context.

 

ii) For Internal Splice:

Nothing: Doesn't include any representation of internal splices in the flattened view.

2D Detail: Displays a pre-defined 2D symbol or detail drawing for internal splices.

Our Choice: Opting for nothing for internal splices is a valid choice. Here's why:

Clarity and Focus: Eliminate unnecessary symbols, keeping the drawing focused on the main wiring layout.

Reduced Complexity: Simplifies the flattened view, especially for designs with many internal splices.

Prioritization: If internal splice details are crucial, they can be documented separately (e.g., dedicated schematics) to avoid overloading the flattened view.

 

C. For Support:

3D Projection: Displays a simplified 3D projection of the support element in the flattened view.

2D Detail: Represents the support using a pre-defined 2D symbol or detail drawing.

Our Choice: Choosing 3D projection for support is a solid decision. It offers these advantages:

Spatial Understanding: Provides a basic 3D representation of the support's location and interaction with the harness, aiding in assembly and understanding.

Clarity and Efficiency: 3D projections are often clearer than 2D symbols, while still being less demanding than full 3D models.

Emphasis on Functionality: Ensures clear representation of support elements, which are critical for harness installation and stability.

Overall, our choices effectively balance clarity, information density, and visual aesthetics in our flattened representation. You prioritize the harness layout while providing essential context for devices and supports without overloading the drawing with unnecessary details.

 

Finally, when we click on 'Okay', Wiring Harness Flattening Parameters will be defined and shown under the Product file as shown below:

We can modify any parameters required at any point during our operation by double-clicking on the Flattening Parameters icon.

 

4. Explaining important toolbar that became active after defining Harness Flattening Parameters:

Flatten Toolbar:

• Harness Flattening Parameters: We have previously defined parameters using this option but under the same toolbar two more options are explained in the following lines. 
• Extract: This button extracts data from the selected geometrical bundle for flattening. This includes information about wires, connectors, supports, and their positions.
• Flatten: This button performs the actual flattening operation based on the defined parameters. You can select specific branches of the harness to flatten or flatten the entire harness.

 

Manipulator Toolbar:

• Arrange the Junction like an Umbrella or Arrange them in Equal Angles: These commands reorganize the connections (junctions) in the flattened harness.

1. Umbrella arrangement: Places all connections around a central point like the spokes of an umbrella.
2. Equal angles arrangement: Positions connections evenly distributed around a circle.

• Rotate or Bend: This command allows you to manually rotate or bend specific segments of the flattened harness for better visualization or to avoid overlapping wires.
• Roll or Quick Roll: These commands roll sections of the flattened harness to adjust their orientation.

1. Roll: Offers more control over the rolling angle and direction.
2. Quick Roll: Applies predefined rolling parameters for faster adjustments.

• Straighten: This command straightens selected segments of the flattened harness, ignoring their original curved paths.

 

Length Toolbar:

Length Tolerance or Remove Length Tolerance: This command either adds or removes a tolerance value to the flattened wire lengths. This tolerance accounts for manufacturing variations and ensures the flattened representation reflects real-world behaviour.

Scale: This command allows you to manually scale the entire flattened harness to a specific size.

 

Synchronization Toolbar:

This toolbar manages the link between the flattened harness and its original 3D model.

Synchronize: Updates the flattened representation based on changes made to the 3D model.

Unsynchronize: Decouples the flattened representation from the 3D model, allowing independent editing.

Update All: Updates all linked data (drawings, bills of materials) based on the latest flattened version.

 

5. Now, we're going to use the 'Extract' command from the flatten toolbar to import our previously created wiring harness assembly as shown below:

Upon importing the wiring harness assembly, a "_Ehf" suffix is automatically added, indicating it's ready for electrical harness flattening. We can now proceed with flattening the harness to our desired configuration.

6. Now, we're going to modify the 'Active Plane' for flattening our wiring harness assembly by replacing the 'xy plane' as our active plane with the top surface of our connector's face as shown below:

 

7. Next, we're going to use the 'Flatten' command from the 'Flatten' toolbar as shown below:

After clicking on the 'Flatten' icon, the 'Flatten' dialogue box will open as shown below:

 

8. Next, we're going to select our bundle segment at one end and then click on the 'Select All Branches' icon in the dialogue box which will select all the bundles that are in continuity with that bundle as shown below:

 

RESULTS AFTER THE FLATTENING OPERATION:

 

9. Next, before we move on to the creation of a drawing sheet on which we are going to represent our wiring harness flattened assembly, we will use the synchronize command to synchronize everything that we have done so far as shown below:

10. Finally, we'll use the 'Save Management' tool to save our files appropriately. 

 

DRAWING WORKBENCH: 

Next, we're going to create a new drawing sheet in the ISO format with sheet style A0 ISO:

 

1. PREPARATION:

File Naming: As per organizational protocol, assign a suitable and informative name to the drawing file, referencing the harness part number, revision, and other relevant details.

View Selection: Since the flattened harness represents a two-dimensional layout, utilize the "Front View" option for optimal representation.

 

2. GEOMETRY EXTRACTION:

Select Source: Access the wiring harness assembly product file.

Surface Reference: Precisely identify the top surface of the connector where the harness was flattened.

Extract Geometry: Initiate the command to extract the entire flattened harness geometry from the selected view.

 

3. DRAWING INTEGRATION:

Import: Upon extraction, CATIA seamlessly imports the harness geometry into the drawing workbench.

Orientation and Placement: Carefully adjust the orientation and position the imported geometry onto the drawing area as per the intended layout.

 

4. ADDING FRAME AND TITLE BLOCK:

Access Sheet Background: Within the drawing editor, navigate to the "Edit" menu and select "Sheet Background" to enter background editing mode.

Insert Frame and Title Block: On the sheet background toolbar, locate the "Frame and Title Block" command. Choose the appropriate frame and title block style based on your organization's standards or preferences. Click "Insert" to place it on the drawing sheet.

Edit Title Block Information: Double-click on individual text fields within the title block to enter and edit relevant information, such as drawing part number, revision, date, and designer name. Ensure consistency with your company's drawing standards.

Return to Working Views: Once the frame and title block are complete,

 

5. ACCESSING DRAWING PROPERTIES:

Invoke Properties: Right-click within the drawing area and select the "Properties" option.

Navigate to View Section: Locate the "View" section within the Properties dialog box.

 

6. ENABLING 3D WIREFRAME DISPLAY:

Identify Dress-Up Features: Under the "Dress-Up Features" sub-section, locate the option labelled "3D Wireframe."

 

7. DETAILED EXPLANATION OF 3D WIREFRAME:

The 3D Wireframe feature provides a comprehensive, skeletal representation of the harness geometry within the drawing. This view offers several advantages:

Enhanced Clarity: It showcases the overall harness structure and path clearly, simplifying visualization and interpretation.

Improved Dimensioning: Facilitates accurate dimensioning of individual wire segments and bends.

Clash Detection: Enables easier identification of potential clashes between the harness and other components in the assembly.

Manufacturing Reference: Serves as a valuable reference for manufacturing personnel during harness fabrication.

 

8. IMPORTANCE OF "ALWAYS VISIBLE":

Selecting the "Always visible" option guarantees that the 3D Wireframe representation remains present in all views within the drawing. This continuous presence ensures consistent clarity and avoids confusion or misinterpretations due to missing information in specific view orientations.

 

Next, I included all the required dimensions for the length of the bundle segment, the length of the corrugated tube, and the names of the connectors, as depicted in the images below:

 

9. FRAME AND TITLE BLOCK:

 

10. BILL OF MATERIALS(BoM):

 

This drawing depicts a flattened wiring harness assembly generated from a 3D model in CATIA V5. To enhance clarity and understanding, particularly in complex harness designs, the following visual coding has been employed:

WIRING HARNESS BUNDLES: Represented by single lines.

PROTECTIVE COVERINGS: Represented by double lines.

This distinction was achieved during the flattening process in CATIA V5's Flattening Workbench by selecting the parameter option to represent "Bundle Segment" as a single line and "Corrugated Tube" (or your specified protective covering term) as a double line.

 

THIS VISUAL CODING OFFERS SEVERAL BENEFITS:

Improved Readability: Differentiates between harness elements and protective coverings, allowing for easier identification and interpretation of the harness layout.

Reduced Clutter: Single lines for bundles minimize visual clutter, particularly in intricate designs with numerous harnesses.

Clear Communication: Ensures proper understanding of the harness structure and potential protection requirements without ambiguity.

 

UNDERSTANDING THE DATA BREAKDOWN OF A HARNESS DRAWING AND THE REASONS BEHIND ITS STRUCTURE IS CRUCIAL FOR SEVERAL REASONS:

EFFICIENT MANUFACTURING:

Clear and complete information: Having all necessary data on various sheets ensures everyone involved in manufacturing (engineers, technicians, assemblers) understands the harness design clearly. This minimizes errors, rework, and delays.

Organized data: Dividing information into logical sheets (layout, connections, parts, assembly) allows for easy access and reference during different stages of manufacturing.

Quality control: Detailed specifications (dimensions, protections, material specs) enable the quality team to effectively inspect the harness and ensure it meets design requirements.

 

STREAMLINED COMMUNICATION:

Standard templates and styles: Consistent formatting across drawings within an OEM facilitates communication and knowledge sharing between teams. Everyone knows where to find specific information regardless of the harness being reviewed.

Table-based data: Presenting connections, BOM, and wire lengths in tables promotes clarity and simplifies data analysis.

Notes and instructions: Additional notes on specific components, assembly instructions, or special handling requirements provide essential context for manufacturers and quality inspectors.

 

REDUCED AMBIGUITY:

Detailed visuals: Drawings with layouts, connector views, and fuse box placements eliminate ambiguity and provide a concrete understanding of the harness structure.

Defined dimensions: Specific measurements prevent misinterpretations during fabrication and ensure proper fit within the final product.

Label views: Marked wires and components minimize confusion and enable efficient assembly and troubleshooting.

 

OVERALL BENEFITS:

Improved quality: Comprehensive data minimizes errors and ensures adherence to design specifications, leading to better product quality.

Reduced costs: Clear communication and efficient manufacturing processes prevent rework and delays, ultimately reducing production costs.

Enhanced collaboration: Standardized data formats and well-structured drawings facilitate information sharing and collaboration between engineering, manufacturing, and quality teams.

In conclusion, understanding the data breakdown and structure of harness drawings is essential for achieving efficient manufacturing, clear communication, and minimized ambiguity throughout the product development process. This knowledge contributes to improved product quality, reduced costs, and smoother collaboration across various teams involved.

 

The Following Data is necessary for OEM Harness Drawings:

1. Drawing Templates & other details such as PartNumber, Revision, Stae Holder, and Sheet details:

• Template: Standardizes formatting, titling, and layout for consistency across drawings.
• PartNumber: Uniquely identifies the harness assembly.
• Revision: Tracks changes made to the drawing.
• State Holder: Indicates approval status (draft, released, etc.).
• Sheet details: Shows the number of sheets and their purpose (overview, layout, BOM, etc.).

 

2. Harness Layout/Line Diagram or Flatten drawing:

• Layout: Depicts complete 3D harness path concerning other components.
• Line diagram: Simplified schematic showing connections between components.
• Flatten drawing: Unfolded representation of the harness for manufacturing.

 

3. Dimensions:

• Critical dimensions of harness segments, bends, clearances, and mounting points.
• Ensures proper fit and function within the assembled product.

 

4. Connector Views (Wire Entry):

• Detailed views of each connector, showing pinouts, wire entry locations, and cable orientation.
• Crucial for correct wiring and assembly.

 

5. Fuse & Relay box view & component placement details, Label Views:

• Location and orientation of fuses, relays, and other components within the harness.
• Label views show text markings on wires and components for identification.

 

6. Protection & Size, Location & Representation of type of protection used:

• Specify the type and location of protective measures like conduit, sleeving, or tape.
• Ensures the harness is shielded from physical damage and environmental hazards.

 

7. Bill of Material (Part numbers, Vendor details, Quality, size, applicability):

• Complete list of components used in the harness, including part numbers, vendors, quality specs, and sizes.
• Facilitates procurement and assembly.

 

8. Connection Table/ Circuit Table with Wire Specifications (Guage Type, Color, Length):

• A table linking each wire to its source and destination circuit.
• Includes wire gauge, colour coding, and precise length for each segment.
• Ensures electrical continuity and correct functionality.

 

9. Wire cut list (Circuit numbers & length):

• Separate list with individual wire lengths based on circuit assignment.
• Used for wire cutting and harness assembly.

 

10. Orientation, Position of fixing parts:

• Specifies orientation and location of tie wraps, clamps, and other mounting hardware.
• Ensures the harness is securely fastened and remains organized.

 

11. Generic Notes for Specification of devices (CAN Cables, Twisting):

• Any additional specifications for specific components or requirements.
• May include details on CAN cable shielding, cable twisting for noise reduction, etc.

 

Limitations of CATIA EHI Module and ECAD interface:

• While CATIA EHI and ECAD tools automate some data generation, they may not cover everything listed above.
• Customizations, component placement, and detailed notes often require manual data entry.

 

COST CONSIDERATIONS:

Some OEMs opt for manual data entry due to budget constraints or specific needs not addressed by existing software.

Balancing automation with manual effort becomes a matter of cost-effectiveness and project complexity.

Remember, providing this comprehensive data ensures clear communication, minimizes errors, and streamlines the harness manufacturing process. It's an essential investment for both quality and efficiency.