Project 1

AIM :

To route the wiring harness on given engine and to prepare flatten view drawing in CATIA V5.

OBJECTIVES:

• Route the wiring harness in given buggati V16 engine.
• Prepare flatten view drawing in CATIA V5.
• Apply all packaging rules and industry best practcies.
• Apply protection coverings as required.
• Provide all necessary reports like clearance, clipping/clamping selection,harness fixing requirements,harness continuity,assumptions if any along with CATIA 3D data.

ASSUMPTIONS and PACKAGING RULES MADE IN THIS PROJECT:

1. Provide clips/clamps as per requirement.
2. Make sure that there is no any fauling case while designing the wire harness.
3. Routing through small structural holes and openings shall be avoided.
4. Additional clips/clamps may be used to avoid fauling case.
5. Give additional slack if needed. 5-10% slack is sufficient.
6. Avoid routing over bolt and bolted joints to avoid harness puncture.
7. Avoid routing on sharp edges or else provide protection over the harness.
8. Wiring harness routing should provide ease in manufacturing, accessibility,easy removal and easy maintenance of attached equipment and wiring harness.
9. Follow the clearance distance and keep away the harness from heat generation components.
10. Protection should be provided as needed according to surrounding temperature.
11. Avoid direct support for harness on fuel lines routed in the engine.
12. Use plastic guiding channels if needed.
13. Branch length should be greater than 50mm.
14. Limit branches to 4 only.
15. Minimum distance between two branch points should be at least 50mm.
16. Minimum distance between clip and branch point should be at least 25mm.
17. Avoid too many sheet metal brackets on the engine. Try to use available threaded bosses on the engine or demand for it.
18. The wiring harness should be easy to assemble and easy to access.
19. While using dummy connectors, ensure that whatever positions you are defining that are practical. Bundle diameters and another placements can be defined properly for the wire harness routing.
20. Avoid the harness routing and clipping in blind zone of operator during harness assembly or in service.

STEP 1: CREATING ENGINE HARNESS CONTEXT

Fig:1

• The engine file is downloaded from the given CAD data. Then new product file is created and renamed it as ENGINE HARNESS CONTEXT, which contains all the assemblies as shown in the above fig:1.
• A Context Assembly will contain Engine Assembly data for Bugatti V16 Engine and Assembly Engine Harness Geometrical Bundle.

STEP 2 : DEFINING ELECTRICAL DEVICES IN ELECTRICAL PART DESIGN WORKBENCH:

4 POLE CONNECTOR (C-1563689-1):

Fig:2

• The connector C-1563689-1 which has 4 terminal is selected according to the requirement. which is electrically defined by using electrical part design workbench.
• The connector connection point and the bundle connection point are also defined.

INTERCONNECTION CONNECTOR (C-776438-4):

Fig :3

• The Interconncetion connector C-776438-4 which has 12 terminal is electrically defined using electrical part design workbench. The CAD data is downloaded from te.com .
• The connector connection point, bundle connection point and the cavity connection point are defined.

CAVITY (C-1924487-2):

Fig :4

• The manifold C-1924487 is defined electrically using electrical part design workbench. Then the cavity is defiend to assembled with the interconnection connector.

Fig:5

• The above fig. shows that the both the connector and the base is assembled using assembly design workbench with respective to the cavity connection point and the cavity.

P CLAMP:

Fig:6

• The P clamp is defined as a support in electrical part design workbench. The entry,exit planes and points also the base plane are defined.

GUIDING CHANNEL TOP AND BOTTOM:

Fig:7

• The above fig. shows that the plastic guiding bottom channel which is also defined electrically as a mounting equipment with 9 bundle connection points.
• A point is created at the entry face and line is created along the direction of channel with respect to the point for 560mm and respective points are created at each exit ways.
• This channel is assembled at the right side of the engine whereas for the left side of the engine the channel bottom is fitted symmetrically.

STEP 3 : ASSEMBLY OF ELECTRICAL DEVICES IN ENGINE:

Fig:8

• All the electrical devices are assembled in the engine appropriately using the mechanical assembly design workbench.
• The above fig. shows that connectors are placed with fuel injector sensors and cam-shaft sensors.
• So there are total 20 connectors used, which are added in the Assembly Engine Harness Geometrical Bundle.
• The tools like manipulation along with compass, snap and smart move features are used to locate all the 20 connectors at their desired locations.

Fig:9

• The above fig. shows the P-Clamp assembly. The P-clamps are also assembled at a correct position in the engine.
• There are 3 P-clamps used in the harness assembly.

Fig:10

• This fig. shows that the mounting bracket is used to mount the interconnection connector.
• The assembly of interconnection connector is mounted using manipulation,compass,snap,smart move tools in mechanical assembly design workbench.

STEP 4 : WIRING HARNESS ROUTING AND PACKAGING:

HARNESS ROUTING:

Harness routing basically shows the path of wiring harness into the vechicle. This is representation of the layout of the wiring harness on the vechicle in geometrical way.

HARNESS PACKAGING:

Harness packaging involves the decisions of harness mountings (use of brackets,channels,guiding devices).It also deals with the clearance management,aesthetic management,thermal management,manufacturability,etc..

Fig: 11

• The assembled electrical devices are routed in Electrical Harness Assembly workbench. There created geometrical bundle,by defining the geomtrical bundle a new multibranchable product is formed from there the harness routing process is done.
• Used diamters for routing are 12mm,10mm,5mm.

Fig :12

• The above fig. shows that the branch definition for creating routing. Ensure that the routing is not distrubed by external surrroundings.
• To maintain from external objects slack is used, recommended slack is between 5 and 10.
• Ensure that the bend radius is set to 1.4 or greater than 1.5 .

Fig:13

• In the above fig. the branching points are created in the routing at a regular distance od 65mm.
• Ensure the routing rules that each branch should be at a distance of 50mm.
• Minimum distance between clips and near branching point should be 25 mm
• Limit the number of branches form the single branching point to be 4.
• Routing should be in one direction, proper routing gives proper flattening.

STEP 5 : APPLYING PROTECTIVE COVERING FOR THE BUNDLES:

Fig :14

• The above fig. shows that the catalogue for protective covering like COT tubes with different diameters.
• The COT tubes helps in protecting the branchables from external elements like heat, accident, human error etc..

Fig: 15

STEP 6: BUNDLE CONTINUITY CHECKING:

• For bundle continuity check, the steps are;
• Edit<Search<Advanced<Electrical

Fig:16

This figure shows that all the bundles are fully connected so it is ready for flattening process.

STEP 7 : ELECTRICAL HARNESS FLATTENING

Fig:17

• The above figure shows that the grometrical bundle is extruded into the Electrical Harness flattening with flattening parameters.
• The flattening parameters and the flatten view are shown below.

FLATTENING PARAMETERS:

FLATTEN VIEW:

Fig : 18

• This figure shows the flatten view of the extruded geometrical bundle. By selecting the face of the interconnection connector and selecting all the branches the flatten view is created.
• Here in the flattening work bench the commands like rotate, roll, quick roll are used.

STEP 8 : DRAFTING THE FLATTEN VIEW:

Fig:19

The flatten view is drafted in the 2D drawing A1 sheet with scale of 1:2 and the parts are addressed.

CONCLUSION:

Hence, the wiring harness for the given Bucatti V16 engine is routed and the flattened using CATIA V5.