Electrical Harness Design

2021-10-20 来源：客趣旅游网

CATIA Electrical Harness Design

TABLE OF CONTENTS

CATIA® V5R19

Introduction..............................................................1

Electrical Harness Design.............................................2Electrical Harness Assembly Workbench.................................4Bottom Toolbar.....................................................5

Measure.....................................................5Electrical Harness Design...................................................7

Defining Geometric Bundles...........................................7Installing Geometric Bundles..........................................17Defining Geometric Bundles in Context.................................21Defining Geometric Bundles on Surfaces................................32Multiple Bundle Segments within a Geometric Bundle.....................44Defining Multi-Branchable Bundles....................................51Bundle Profiles.....................................................63Bundles on Curves..................................................79Modifying Multi-Branchables.........................................82Supports..........................................................97

Supports inside the Geometrical Bundle...........................97Supports Outside the Geometrical Bundle.........................103Adding Supports............................................109Removing Supports..........................................120Multi-Position Supports.......................................123Adaptive Supports...........................................128Position Bundles in Supports...................................134Local Slack.................................................151Protective Coverings...............................................157

Modifying Protective Covering.................................164Protective Covering with Supports..............................165Protective Covering with Adaptive Supports......................169Adjusting Protective Coverings.................................171FLEX Algorithm............................................175FLEX Algorithm with Constrained Length........................181Geometrical Bundle Analysis........................................185

Related Objects.............................................185Inertia Measurements.........................................192Geometrical Bundle Equivalents................................194Clash Analysis..............................................197Modifying Geometric Bundles........................................201

Table of Contents, Page iCATIA Electrical Harness Design

CATIA® V5R19

Electrical Flattening......................................................223

Harness Flattening Parameters........................................223Extracting........................................................231

Extract with Supports.........................................235Flattening........................................................241Flattening Orientation..............................................257Flattening Scaling.................................................260Roll - Rotate - Scale................................................267Synchronization...................................................302Problems..............................................................317

Problem #1.0.....................................................317Problem #2.0.....................................................318Problem #3.0.....................................................319Appendix A............................................................321

Equipment & Systems - Electrical Harness Discipline - Electrical Assembly Design -General....................................................321Equipment & Systems - Electrical Harness Discipline - Electrical Assembly Design -Electrical Library Access......................................322Equipment & Systems - Electrical Harness Discipline - Electrical Harness

Installation - Harness Management..............................323Equipment & Systems - Electrical Harness Discipline - Electrical Harness Flattening

- General...................................................325

Table of Contents, Page ii©Wichita State University

CATIA Electrical Harness DesignIntroduction

CATIA Version 5 Electrical Harness Design

CATIA® V5R19

Upon completion of this course the student should have a full understanding of thefollowing topics:

-- ---Define geometric bundles

Define complete harnesses of a dynamic lengthDefine complete harnesses of a static lengthDevelop harnesses within the context of a productDevelop and utilize a harness in multiple products

Introduction, Page 1CATIA Electrical Harness DesignElectrical Harness Design

CATIA® V5R19

Defining an electrical harness requires two steps. You must first define the required

connectors and connection points. Once you have these connections, you are ready to begindefining the geometric bundle that links the various connection points. These geometricbundles will behave as a space reservation for the wiring they will contain. In this section ofthe course, you will not be defining the actual wires within the geometric bundle, but ratherjust the overall size and shape of the geometric bundle that will contain the wiring. There are two workbenches involved in electrical harness design. They are the ElectricalHarness Assembly and the Electrical Harness Installation workbenches. The Electrical

Harness Assembly workbench will allow you to work with the geometric bundle as a whole. The Electrical Harness Installation workbench will allow you to define the specific bundlesegment and route the bundle. The two workbenches are used simultaneously to define thegeometric bundle. Although the Electrical Harness Installation workbench is a separateworkbench, it is generally only accessed through the Electrical Harness Assemblyworkbench when defining a specific bundle segment. This is a similar behavior to theSketcher and Part Design workbenches. You generally do not access the sketcher

workbench directly, but instead you access sketcher through the Part Design workbench. Inour case, the Electrical Harness Assembly workbench works in the product environment,whereas the Electrical Harness Installation workbench works with a specific branchable partin the product.

In this course, you will not be defining the specific wires within the geometric bundle. Instead, you will be defining the bundle as a whole for space reservation and connectivityinformation and not to define pin to pin connectivity. To define pin to pin connectivity youwill need to study the Electrical Wire Routing workbench. With that said, keep in mind,you can always define a geometric bundle per wire if desired. This will emulate definingspecific connectivity, however, you will find that it will require a lot of time and work whendealing with smaller wires.

Introduction, Page 2©Wichita State University

CATIA Electrical Harness DesignElectrical Harness Design

CATIA® V5R19

In this section, you will look at developing a simple single branch harness. Keep in mind,you will be using both the electrical harness assembly and electrical harness installationworkbenches. These two workbenches work together to define the harness and the bundles. Defining Geometric Bundles

In this first exercise, you are going to look at creating a basic geometric bundle between twoconnectors. As you continue through this book you will find the harnesses and bundlesbecoming more and more complex as the options are covered in more detail.

Create a new product. Name the product Harness 1. This new product will serve asyour first harness.

If not already there, switch to the Electrical Harness Assembly workbench. This willallow you to build the electrical harness. It is available under the Equipment & Systemssolution and the Electrical Harness Discipline.

Notice there is not an icon to insert an existing component into the product. This is not anissue since you can use the Insert pull down menu or right click on the product. Right click on Harness 1 in the specification tree and select Components, ExistingComponent. This will display the File Selection window.

Single Bundles, Page 7CATIA Electrical Harness Design

CATIA® V5R19

Insert the 4 Pin Mount Connector document from the Electrical Harness I directory. This will be a simple four pin mounting connector.

Remember, you can also insert components from the catalog.Select the Catalog Browser icon from the bottom toolbar. Catalog Browser window.

This will display the

Open the Electrical Catalog from the Electrical Catalog directory. Open the

Connectors chapter and the Single Insert Connectors family. Remember, to open thechapters and families, all you need to do is double select on them.

Find the 4 Pin Connector and double select it, select OK to insert it into the product. Close the catalog browser when done. This will insert a connector into the assembly aswell.

Single Bundles, Page 8©Wichita State University

CATIA Electrical Harness Design

CATIA® V5R19

Using the compass or other manipulation tools, manipulate the 4 pin connector to theapproximate location shown. The exact position is not required, just separate the twoparts.

At this point, you have simply added a few connectors to your product. Now you are goingto turn the product into a geometric bundle.

Select the Geometrical Bundle icon, then select Harness 1 from the specificationtree. Notice a few things happen in the specification tree.

With the default options, the product name will automatically change to GeometricalBundle1. You can change the name of the bundle to anything you want.

Change the name of Geometrical Bundle1 back to Harness 1. This will change the

product name back. Remember, to change the name, you will have to go to the properties ofthe product.

At this point, you are ready to define a bundle between the two connectors.

Single Bundles, Page 9CATIA Electrical Harness Design

CATIA® V5R19

Select the Bundle Segment icon. This icon may be under the multi-branchabledocument icon. When you select the icon, a few things will happen.

By selecting on the bundle segment icon, you will automatically be switched into the

Electrical Harness Installation workbench, as well as have a bundle segment created in thespecification tree.

At this point, you are ready to define the bundle segment. Take a moment to examine theBundle Segment Definition window.

Single Bundles, Page 10©Wichita State University

CATIA Electrical Harness Design

CATIA® V5R19

NameDiameterSectionBend RadiusBend Radius RatioBuild Mode

Mode

SlackLengthBendSlack (%)

Specifies the name of the bundle

Specifies the outside diameter of the bundleSpecifies the cross sectional area of the bundle

Specifies the minimum bend radius allowed for the bundle

Defines the bend radius based on the diameter of the bundle. A ratioof 1 will set the Bend Radius to the same size as the bundle Diameter.

Bundles are computed with a minimum distance, andthen a percentage of slack is added to the bundleBundles are a set length, regardless of the amount ofslack

CATIA will compute the minimum length possiblewhile respecting the Bend Radius

Defines the percentage of slack between connection points. Although 0% is allowed, there needs to be a slack of at least.1% to avoid update errors with Harness Flattening tools.

Single Bundles, Page 11CATIA Electrical Harness Design

Length

CATIA® V5R19

Defines the length of the bundle when in Length mode. Thelength must be as long, or longer than the distance betweenthe two connection points.Defines the bundle route

Allows for the bundle to swap sides of a surface that is attached to thebundle

Allows selection of a curve to define the bundle route

Route Definition Bundle Segment...External Curve

Many of these parameters will be tested further once the route is defined.

Change the Name to Harness 1 Bundle. This will define the name for the bundle. Unless already set, change the Diameter to 0.5in. You will notice the Section will

automatically change to 0.196in2. This is due to the two fields being computed based oneach other.

Change the Bend Radius to 0.5in. Typically your bend radius will be equal to or greaterthan the diameter. If you set the bend radius smaller than the diameter, CATIA will displayan error message about the impracticality of this.

Change the Build Mode to Slack, and set the Slack percentage to 10. This will have allthe bundle options defined. Now to generate the bundle via the route definition.

Single Bundles, Page 12©Wichita State University

CATIA Electrical Harness Design

CATIA® V5R19

Select Route Definition. This will allow you to define the route for the bundle. The RouteDefinition window will display. Take a quick look a the various options in the RouteDefinition window.

Routed Objects / Tangent Dir.Add afterAdd beforeReplaceRemove

Geometry on support

This area displays the objects and points for the routedefinition

Adds points and connection points after the selectedpoint

Adds points and connection points before the selectedpoint

Replaces the selected point with another selectionRemoves the selected point

Allows bundles to be placed on surfaces or othersupport parts

Single Bundles, Page 13CATIA Electrical Harness Design

By selecting the More>> button, you get a few additional options.

CATIA® V5R19

Tangent management

Constraint type

Explicit

Defines the type of tangency to be defined

Tangency is defined via a manual vector definition. Tangencydefinition is defined through a right click in the TangentDirection field.

From curve

Tangency is defined from a curve or line selection. WhenFrom curve is selected, the Tangent direction changes toElement.

Slack management, Ignore SlackIgnores or removes slack between points

Single Bundles, Page 14©Wichita State University

CATIA Electrical Harness Design

Offset Management at Creation

Automatic

Automatic with Safety MarginManual

Now you are ready to define the route.

Lays the bundle on the surface

CATIA® V5R19

Lays the bundle on the surface with an

additional offset of the safety margin distanceAllows you to specify a specific distance forthe bundle to exist off the surface

Select the 4 pin mount connector. Notice the connector is automatically added to theRoute Definition window, as well as the bundle connection point is automatically defined.

Anytime you select an electrical device with a bundle connection point, the connection pointwill automatically be selected and the tangent direction will automatically be defined in theInitial Condition direction defined in the bundle connection point’s placement constraints. Select the 4 pin connector. This connector will also be defined in the routed objects. Notice the bundle is now present.

Note: The physical shape of the bundle may vary based on the position of the twoconnectors.

Single Bundles, Page 15CATIA Electrical Harness Design

CATIA® V5R19

Select OK to the Route Definition window. This will take you back to the Bundle SegmentDefinition.

Select OK to the Bundle Segment Definition window. This will have the bundle defined. Notice that you are still in the Electrical Harness Installation workbench.

Select the Exit icon. workbench.

This will take you back to the Electrical Harness Assembly

Save your harness. When you save, you will be prompted to save the Harness 1 Bundle aswell. Be sure you save the bundle into the same directory. Save Management would be agood option to use when saving your bundles. Leave your harness open, it will be used inthe next section.

Single Bundles, Page 16©Wichita State University

CATIA Electrical Harness Design

Protective Coverings

CATIA® V5R19

There may be many times when you want to add protective coverings to your bundles. Youhave the ability to add protective tape or a protective corrugated tube to your harness. Protective coverings are instantiated from an electrical catalog. By default, the protectivecovering will cover the entire bundle segment, however, it can be adjusted to cover justparticular segments.

Open the Protective Covering document from the Protective Covering directory. This is a simple harness that has several bundle segments of various sizes.

In the Electrical Harness Assembly workbench, select the Protective Covering icon.

This will display the Instantiate Protective Covering window. Take a moment to lookat the various options in this window.

Protective Coverings, Page 157CATIA Electrical Harness Design

Protective covering

Catalog selectionBundle segmentsTape Parameters

Layer NumberTaping angle

CATIA® V5R19

Defines the protective covering being applied. Thisprotective covering must be selected from a catalog.Display the catalog browser for protective covering selectionSpecifies the bundle segments that will have protectivecovering applied

Defines how many layers of tape to that are to beapplied

Defines the angle to which the tape is applied. Ataping angle of 0deg indicates the tape is appliednormal to the bundle. A taping angle of 90deg wouldindicate that the tape is run straight along the lengthof the bundle. You must define an angle between 0and 90.

Defines the amount of overlap for each strip of tape

Overlapping

Note: Taping angle and Overlapping are computed based on each other. Changing onewill automatically recompute the other parameter. When a corrugated tube is selected, thetaping parameters go away.Protective Covering Information

Covered lengthTotal tape length

Defines the length of the protective covering inmillimeters

Defines the overall length of the tape used inmillimeters

Select the catalog selection icon from the Instantiate Protective Covering window. This will display the Catalog Browser window.

Select the Browse Another Catalog icon, then select the Electrical Catalog found inthe Electrical Catalog directory.

This will open the class electrical catalog.

Double select the Protective Covering family. This will display all the protectivecoverings in the catalog.

Find and double select the 0.5\" Corrugated Tube in the catalog.

Protective Coverings, Page 158©Wichita State University

CATIA Electrical Harness Design

This will change the Protective Covering window for the corrugated tube.

CATIA® V5R19

Notice all the tape parameters are now gone.

Select the yellow bundle segment. This will cover the yellow bundle with the corrugatedtube.

You will also notice the Start and End Extremity text on the ends of the tube. Theseextremities allow you to adjust the endpoints of the tube.

Double select the End Extremity. This will display the Create Point on Curve window.

Protective Coverings, Page 159CATIA Electrical Harness Design

Curve

Defines the curve that the tube or tape runs along

Point to reference

RatioLengthMiddle PointReference

Reference point

CATIA® V5R19

Defines the ratio or percentage of the curve length theextremity stops

Specifies the geodesic distances from the end of the curve tothe end of the tube or tapeSets the ratio to 0.5

Defines the point in which the length or ratio is based

Change the Length to 0.5in and then select Apply. Notice the corrugated tube shortensby a half inch.

You will also notice that while the Create Point on Curve window is open, you can

dynamically choose your endpoint by sliding your mouse along the centerline of the bundlesegment.

Select the Middle Point button, then select OK. This will put the tube along half of thebundle segment.

CATIA Electrical Harness Design

CATIA® V5R19

Select OK to the Protective Covering window. This will establish the protective covering.

Select the Protective Covering icon again, then select the 0.5 Electrical Tapeprotective covering from the same catalog as before. You will have to go to thecatalog as before.

Notice the tape parameters are still available.

Set the Taping angle to 20deg. Notice the overlapping is automatically computed.

Protective Coverings, Page 161CATIA Electrical Harness Design

CATIA® V5R19

Select the yellow bundle again. This will wrap the bundle with the electrical tape.

Notice the tape runs under the corrugated tube.

This is the default behavior of the electrical tape. You can place electrical tape on top ofthe corrugated tube, you just have to adjust it afterwards. This will be done later. Select OK. This will leave the electrical tape wrapped around the bundle.

CATIA Electrical Harness Design

CATIA® V5R19

Select the Protective Covering icon again, then select the .375 Corrugated Tubefrom the catalog. Notice that you have two bundle segments running to one connector.

Select the dark blue and the orange bundle segment. In this case you will notice thatthe corrugated tube runs the full length of both bundle segments.

As long as the bundle segments are all part of the same branchable, then you can applyprotective covering to them. When you have multiple branches, you cannot apply the

protective covering to them at the same time. You must apply the covering independently. Select OK when done.

Protective Coverings, Page 163CATIA Electrical Harness Design

Modifying Protective Covering

CATIA® V5R19

Select 0.5 Electrical Tape from the specification tree, then select the ProtectiveCovering icon. This will display the Instantiate Protective Covering window for theelectrical tape.

Select the aqua bundle segment. Since this is also on the same branchable, then you canadd it to the tape definition.

Notice the tape does not change size for the other bundle segment.

Double select the End Extremity. This will display the Create Point on Curve window. Change the Length to 8.0in, then select OK. Now you can clearly see that the tape stays aconstant size as it crosses from one sized bundle segment to the next.

CATIA Electrical Harness Design

CATIA® V5R19

Select OK to the Instantiate Protective Covering window when done. This will completethis exercise. Next, you will look at combining protective covering and supports. Save and close your document. Protective Covering with Supports

There may be many times when you want to apply protective covering around your bundlejust at the support locations. This keeps the bundle protected in just the areas susceptibleto cutting and damage by the support.

Open the Protective Covering document from the Protective Covering with Supportsdirectory. This is a simple bundle that has been ran through a series of supports.

In this case, you want to place protective covering over the geometric bundle, but only nearthe supports. This is possible by modifying the start and end extremities. Select the Protective Covering icon, then select the bundle segment. define what bundle will have protective covering added.

This will

Select the Catalog Selection icon, then find and double select on the Duct Tapeprotective covering. You can also select the Duct Tape, then select OK when done. At this point, the entire bundle segment will be wrapped in duct tape. This needs to beedited to accommodate the need for tape just around the supports.

Protective Coverings, Page 165CATIA Electrical Harness Design

CATIA® V5R19

Double select the Start Extremity. This will display the Create Point on Curve window. Select the Reference point field. In this case, rather than adjusting the length or the ratioof the protective covering, you will adjust the reference points to keep the protectivecovering just in the area needed.

On the last support, the one closest to the 3-way plug, select the point on the right sideof the support. This point is shown here.

This will change the Reference point to Point.8.

Select Apply. Notice the covering now starts at the support.

CATIA Electrical Harness Design

Now to adjust the starting point back a little.

Change the Length to -1.0in. Notice a Warning window is displayed.

CATIA® V5R19

Since the start and end extremities are generally at the end of the curve, you cannot define anegative value. Since you have moved the start extremity towards the center of the curve,you can now define a negative number, however, CATIA is still limiting your range. Youwill suppress the range so that you can define a negative value.

Select OK to the warning. Right click in the Length field, then select Range and thenSuppress. This will remove the range limits.

Key -1in for the Length. Select Apply when done. Notice now the protective coveringstarts an inch before the support.

Protective Coverings, Page 167CATIA Electrical Harness Design

CATIA® V5R19

Select OK then double select the End Extremity. You will be doing the same thing forthe end extremity.

Select the Reference point, then select the point on the opposite side of the support. This will stop the bundle just after the support.

Suppress the range of the Length, then change the Length to -1.0in. Select OK whendone. This will have the start and end of the protective covering defined.

Change the Taping angle to 1.0deg. This will wrap the tape nearly straight on the bundle.Change the Layer number to 5.0. This will indicate that five layers of tape will beapplied to the bundle. Notice the thickness of the tape is increased as layers are added.

Select OK when done. This will establish the protective covering needed around thebundle segment near the support.

Using the same steps, define protective covering around other supports.

You could optionally arrange the bundle segment within the support and the protectivecovering will move with it.

因篇幅问题不能全部显示，请点此查看更多更全内容

查看全文

全部栏目

Electrical Harness Design