Project 1

Objective:

Application of packaging rules and Industry Best Practices for Wiring Harness routing for a given engine.

Theory:

The given engine will have the following requirements:

• 16 connectors, 8 on each side for each cylinder. A 4-pole connector is selected for this as it is most commonly used for fuel injector connections.
• 4 connectors, 2 for each engine block. These are most likely the camshaft connectors, 4-pole connectors selected here too.
• 3 connectors possibly for engine speed, coolant, temperature, etc. applications. 2 pole connectors are used here.
• 1 inter-connection connector from outside the engine housing to the engine.
• Two guiding channels to house the bundles that route to each cylinder.
• P-clamps and clips as required.

Packaging rules:

• Easy manufacturing, installation, removal, and maintenance of the product.
• Routing shall be designed to minimize chaffing and handling during installation.
• Providing required slack.
• No case of fouling while designing the wiring harness in the CAD environment. Additional clips/ clamps may be used to avoid fouling.
• Minimum branch length of 50mm.
• Minimum length between branch points and supports of 25 mm.
• All components can be sourced easily. Avoiding custom parts and assemblies.

Conclusion:

The wiring harness was designed, flattened, and depicted as a draft drawing with BOM.