Project 1

AIM : 

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

OBJECTIVE:

• Route the wiring harness in the given engine(V 16).
• Apply all packaging rules and industry best practice

Example:

• Minimum 50mm between bundle segments
• Not collide with other components
• Avoid tension on wiring
• Provide clip and clamp
• Give required slag
• Give required clearance
• Give the required bend radius of 1.4 times of wire diameter
• Avoid temperature area using clearance and COT tube
• The minimum distance between the clip and the branch point should be at least 25mm.
• Avoid direct support for harness on fuel lines routed in the engine use component like channels(to create path and clearance)
• Path easy to maintain

• Apply protection coverings(COT tubes) as required.
• Provide all necessary factors like clearance, clipping/clamping selection, harness fixing requirements, harness continuity, and assumptions if any along with CATIA 3D data.   
• Prepare the flatten view drawing in CATIA V5.

Analysis of the engine component used for wiring hardness

Connecting ports

• 24 ports are connected with the engine block (18 positions and 4 heat ) ports are used for.
• 3 ports are used to collect data for power transmission and speed

Initialization :

Create Context assembly which contains geometrical assembly and engine

The geometrical bundle contain connectors and clamp used for wiring hardness

Connectors, support and part used :

• CONNECTOR (C-1563689-1)

Which contains 4 terminals used as per the requirements and define the connector and create the bundle entry point for the assembly.

• CONNECTOR (C-776438-4):

Which is 12 terminal connector used for a main power source for the wiring assembly

• CAVITY (C-1924487-2):

Which is the cavity used to place the C-776438-4. The cavity should define as the mount.

• 2 Pole connector:

Which contains 2 terminals used as per the requirements and define the connector and create the bundle entry point for the assembly.

• P Clamp

which is defined as support. define requires 2 points and 3 planes for the entry, exit planes and points also the base plane are defined.

• Guiding channels

                                                        Channel Top

                                                         Channel Bottom

Which is used to route the bundle in an organized manner and create the required clearance channels should define as mount and define the bundle entry and exit points.

 Harness routing 

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

 Harness packaging      

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

 

Steps for routing and packing

• Place the connectors, support, and clamps in the required places
• Create the bundle in an appropriate manner and size.
• The main branch bundle at 15mm dia,sub-branch bundle(for channel) starts at 10 mm and reduces until 5mm respectively as the connections. And the distance also fixed at the channel as 67 mm and slag are respectively defined as per the requirement of 50 mm bundle length

 

• Connectors are connected with 5 mm of the bundle (except the power entry and exit connector)

COT tubes (Orange Colored part on the routing image)

COT tubes help in protecting the branches from external elements like heat, accidents, and human error.

Bundle connectivity check:

If the bundle is not connected properly, flattering can't be performed 

The wiring hardness is imported into flatten workbench and flattened which express as Ehf.

 

Flatten diagram drafted on A0 sheet at a scale of 1:2

Conclusion:

The given engine of V16 is successfully routed and flattened