Project 1

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

Objective - The objective of the project is to route the wiring harness on the given Engine and prepare to flatten the 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, and harness continuity should be provided in order to design the wiring harness

Engine Description:

1. 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.
2. There is a total of 16 injectors where 8 injectors are used for 8 cylinders on the right side and 8 injectors are used for another 8 cylinders on the left side.
3. Also, there are 4 cam-shaft sensors, so there is a total of 20 sensors that we have to connect electrically.
4. Generally, 4-pole connectors are used for fuel injectors of the engine.
5. 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.
6. The plastic guiding channel used in this harness should be made of a material that can withstand at least 150 degrees Celsius.
7. The bend ratio for all bundle segments should be 1.4

Assumptions-

1. Provide clips/clamps as per requirement.
2. Make sure that there is no falling case while designing the wire harness. Additional clips/clamps may be used to avoid fauling cases.
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 the surrounding temperature.
8. Avoid direct support for harnesses on fuel lines routed in the engine.
9. Use plastic guiding channels if needed.
10. The branch length should be greater than 50mm.
11. The minimum distance between two branch points should be at least 50mm.
12. The minimum distance between the clip and the 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 placement 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 a harness channel that can be used to route and protect the wire harness effectively

Steps for project completion:

Step 1: defined all the needed components as electrical components. the defined components are connectors, P clamp, Firr T clip, etc

Step 2: create a context assembly as an engine _Assy

Step 3: Create sub-assembly of the engine and other components.

Step 4: Create a geometrical bundle assembly and insert all the needed components in it.

Step 5: connected all the components as are shown below

Step 6: checked connectivity of all bundle segment

Step7: create flattening

Step 8: create drawing