Challenge

Project 1

SSanjit Tarafdar7 Dec 2022

Objective:

Route the wiring harness on given V-16 engine and prepare flatten view in CATIA. Apply all packaging rules and industry best practices.

The given V-16 engine consist of following electrical components to which harness routing is required.

8+8 fuel injectors on the engine cylinders for both sides of the engine block (16 injectors), which are connected by a 4 pole connector with the wiring harness.
2 camshaft sensors on each engine block (4 camshaft sensors), which are connected by a 4 pole connector with the wiring harness.
Engine coolant sensor at the centre of the engine between the two blocks, which is connected by a 2 pole connector, with the wiring harness.
Engine oil temperature and pressure sensor fitted at the oil sump of the engine on both engine cylinder blocks, which are connected by a 2 pole connector with the wiring harness.
1 sensor to measure vehicle speed, which is connected by a 2 pole connector, with the wiring harness.
1 sensor to sense neutral positon of the transmission assembly, which is connected by a 2 pole connector, with the wiring harness.
An interconnection connector to connect engine harness system to vehicle harness system.

Other equipment required to complete the wiring harness routing

Guiding channels to protect the harness routing from high heat zones of the engine wherever necessary.
P-clamps to provide positive clamping and ensure clearance management for the routing wherever necessary.
Sheet metal brackets such as L-clips to mount the interconnection connector.
Mounting clips to mount the connectors whenever required.
Corrugated protection tubes to protect the wiring harness.

Assumptions and packing rules :

Wiring harness routing shall provide ease in manufacturing, accessibility, easy removal and easy maintenance of attached equipment and routing harness.
Wiring harness should be routed in such a way that it is easy to assemble on a vehicle.
Wiring harness should be kept away from sharp environments like sheet metal brackets, panel edges, corners etc.
Avoid harness routing and clipping in blind zone of operator during harness during installation.
Ensure that routing meets the clearance requirements with the different surrounding parts.
Routing shall provide enough slack for each branch to avoid additional stress on wire and terminal crimping joints but ensure that extra slack does not cause wiring harness foul with surrounding parts and impact desired clearance requirements.
Enough clamps should be provided to ensure the positive clearance with surrounding and safety of wiring harness.
Use of plastic guided channels are recommended to meet the clearances in critical areas if it is difficult to achieve by use of clamps.
Branch length should be minimum 50mm.
Minimum distance between clip and nearest branching point should be 25mm.
Minimum distance between two breakouts should be 50mm.
Limit the no. of branches from single branch point to 4.
Ensure that harness protection is provided according to surrounding temperature, manufacturability and expected reliability.
The min. bend radius is to be 1.4.
Consider min 5% slack in the wiring harness if needed.

Procedure:-

For the wiring harness getting input as v16 engine block as shown in figure below:-

Connectors Requiremet for the wiring harness with specified electrical component and give Bundle connection points and connector points and extra parameters such as cavity points etc. as shown in figure below.

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