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Exterior of a black sedan in a studio

Case Study

Designing a Wiring Harness Channel in 3D

EASi helps a Tier-2 automotive supplier by developing enclosure designs for a wiring harness channel that would be packaged on the floor of the automobile. 

The client and challenge
The customer, a Tier-2 automotive supplier to GM, required support in designing wire harness channels. It needed to develop enclosure designs for a wiring harness channel that would be packaged on the floor of the automobile. The final design needed to incorporate minimum and varying surface area to achieve several sections of wiring harness bundle throughout the channel. Design for manufacturing (DFM) within the injection molding process also needed to be considered.

The solution
EASi used an established team of automotive design resources in our Troy, Mich., delivery center to complete design and analysis work using computer-aided engineering (CAE). EASi used surfacing skills to achieve the complex geometry required for the variation of the volume of wiring bundles. In addition, the lower channel had to be designed to provide 0.5 mm clearance from the floor panel to achieve the required surface area.

EASi’s designs made provisions for the common attachments and openings for access to avoid any interference within the surrogated data. This included standardizing attachments across the geometry for assembly. Final models were fully parametric, history-based and completed in CATIA V5.

The results
EASi generated surfaces from the floor panel by offsetting the required clearance. The surface model was created and converted to solid design out of those surfaces. The design was developed with required surface area at all sections by keeping minimum clearances with environment components.

Standard snapping body was created and used across the channel by positioning and orienting it in the assembly. Design and drawings were carried out in three phases: Concept, Prototype and Production releases.

Expertise
CATIA V5