Hello, my name is Abhishek Jadhav, and I work in the Powertrain system for Team Kratos Racing Electric. I would be making a 3-part series cover how to design a Complete Electrical Wire-Harness for a Formula Student Race Car.
In this would be part 2/3, here we would be focusing on the converting the 2D diagram into a 3D diagram.
Harness Design procedure:
The complete harness is designed on 3D Experience using CATIA Electrical System Design, CATIA Electrical 3D Design, CATIA Electrical 3D Part Design, and CATIA Generative Electrical 3DDesign.
The complete design procedure is divided into 3 parts:
- Logical Diagram: Creating a wiring diagram i.e., a 2D Diagram of the complete harness.
- Physical Diagram: Converting the 2D diagram into a 3D diagram i.e., routing the complete harness on the vehicle in 3D.
- Manufacturing sheet: Creating a manufacturing sheet according to the harness subparts.
B. Physical Diagram:
After creating the complete 2D wire harness this is the process where the 3D harness process is initiated. Here all the electrical properties are added to all the connectors, electrical equipment and supports that are to be added. A function called “Logical to Physical Assistant "is used and its aim is to synchronize the logical and the physical parts of a system, here a 2D schematic and the associated 3D design. It is available in the Generative Electrical 3D Design app. As all the wire to wire and wire to connected destinations are defined in the 2D harness, the wire conduit to connector is routed with respect to the vehicle CAD after all the components are placed fixed. After which all wires are routed to their destination via their respective conduits and connectors in the shortest path automatically. After this the exact wire and conduit lengths and width are calculated. From the software it does a “Continuity check” where it checks if all the pins of the connector are connected to the correct destination via the correct wire as the routing process is an automatic process.
Complete 3D Harness on CATIA Electrical 3D Part Design
Electrical Connectivity check on CATIA Electrical 3D Design
Edu
