Challenge

Project 1

RRagupathi Ragu14 Dec 2022

PROJECT-1

Aim- To route the wiring harness on given Engine and flatten view drawing in CATIA V5.

Objective- The objective of the project is to route the wiring harness on given Engine and prepare flatten view drawing in CATIA V5. All types of packaging rules have to be considered while routing the harness. Also, Industry best practices should be demonstrated in design. All the necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design wiring harness.

The above figure shows the 16 valve Bugatti Engine where 8 cylinders are placed on the right side and 8 cylinders are placed on the left side.

There are total 16 injectors where 8 injectors are used for 8 cylinders on right side and 8 injectors are used for another 8 cylinders on left side.

Also there are 4 cam-shaft sensors, so there are total 20 sensors that we have to connected electrically.

Generally, 4-pole connectors are used for fuel injectors of the engine.

The engine will also have an interconnection connector which will connect the engine to other parts of the vehicle. We will be using a 12-pole electrical connector with a mounting clip feature as an interconnection connector.

The plastic guiding channel used in this harness should bemade of a material that can withstand at least 150 degree Celcius.

The bend ratio for the all bundle segmets should be

Assumptions-

1.Provide clips/clamps as per requirement.

2.Make sure that there is no any fauling case while designing the wire harness. Additional clips/clamps may be used to avoid fauling case.

3.Give additional slack if needed. 5-10% slack is sufficient.

4.Avoid routing over bolt and bolted joints to avoid harness puncture.

5.Avoid routing on sharp edges or else provide protection over the harness.

6.Follow the clearance distance and keep away the harness from heat generation components.

7.Protection should be provided as needed according to surrounding temperature.

8.Avoid direct support for harness on fuel lines routed in the engine.

9.Use plastic guiding channels if needed.

10.Branch length should be greater than 50mm.

11.Minimum distance between two branch points should be at least 50mm.

12.Minimum distance between clip and branch point should be at least 25mm.

13.Avoid too many sheet metal brackets on the engine. Try to use available threaded bosses on the engine or demand for it.

14.The wiring harness should be easy to assemble and easy to access.

15.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.

16.If the packaging area is too tight and there are many packaging constraints then we can think of creating harness channel which can be used to route and protect the wire harness effectively.

Electrical define