Project 1

Bugatti V16 Engine wiring Harness Routing in Catia v5

AIM-To Route the Wiring Harness of Given Bugatti v16 engine and creating The Flatten view drawing Catia v5.

OBJECTIVE- The objective of the project is to Design and Develop route the wiring harness on given Bugatti V16 Engine and prepare flatten view drawing in CATIA V5. All types of packaging rules have to be considered while routing the harness. All the necessary details like clearance, clamping selection, harness fixing requirements, harness continuity should be provided in order to design wiring harness.

INTRODUCTION- A wire harness, also commonly referred to as a wiring harness, is an exterior sheath used to cover some types of electronic wires.

An engine wiring harness is constricted wires, cables, terminals, and connectors controlling a vehicle electrical system.it relays electrical power and control information to components such as batteries, alternators, fuel injector, fuses, audio systems, blower motors, fuel injectors and computers.

It manages the key functions around the engine including engine controller, oil controller gate, transmission plug housing, air pipe sensors, pressure sensors and water temperature sensor.

An engine wiring harness is how each part of your vehicle gets electricity. It is crucial to help the vehicle run and it’s usually made of a heat-resistant rubber to handle the high and low temperatures that vehicles often experience. The vehicle needs more than the engine, and it requires a lot of electricity for certain things to function, like the radio or lights. Beyond that, battery, starter, and even alternator run on power, which is provided by the engine.

The above figure shows that

• Engine where 8 cylinders are placed on the right side and 8 cylinders are placed on the left side.
• There are total I6 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 is total 20 sensors that we have to connected electrically.
• Generally, 4pole 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 be made of a material (Thermoset or Thermoplastic) that can withstand at least 150 degrees Celsius.
• The bend ratio for the all-bundle segments should be 1.4

Assumption For wiring harness routing

1 Provide clips/clamps as per requirement.

2. Make sure that there is no any fouling case while designing the wire harness. Additional clips/clamps may be used to avoid fouling 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 recommended to meet the clearances in critical areas if it is difficult to achieve by use of clamps.
10. Branch length should be greater than 50mm.the no of branch from a single branch point to 4.
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 other 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.

Other equipment used complete the wiring harness-

• Guiding channels to protect the harness routing from high heat zones of the engine 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.

DESIGN METHODOLOGY-

STEP 1- Download the Engine Cad data and all other cad data from given sources.

Step 2- Download the required Connectors from the source and convert the mechanical connectors electrically by using the electrical part design work bench by following below steps.

• First download the connectors and mounting clip from the given link source.
• Get into the mechanical part workbench to create required geometrical parameters.
• Create connector connection point and bundle connection point on the required sides of the CAD part.
• Create axis system on the connector connection point such a way that the Y coordinate facing normal to the connector face, X coordinate facing towards the locking mechanism and Z coordinate facing to the top.
• Create cavity connection point for connectors having the cavity for mounting clips Using the geometrical parameters created, Define part as electrical connector.
• Define bundle connection point.
• Define connector connection point.
• Define cavity connection point.

STEP 3- Download and Define the plastic channel electrically Procedure for electrically defining the Channel Create bundle entry point and exit point. Create a line curve between the main entry and exit points for creating the multi-branch able using external curve inside the channel Create 8 bundle entry points on the openings for connecting the injector connectors. Using the geometrical parameters, define the channel electrical using the define mounting equipment option. Define bundle entry points using the “define bundle connection point option”.

Then Create new product assembly top and bottom part assembly.

Create Channel symmetrical assembly and define the symmetry bottom channel electrically using define mounting equipment option and also create all the required geometrical parameters on it. For another side.

STEP4-Create new product file for interconnection connector and cavity assembly.

STEP 5 -Creating the context assembly Context assembly is nothing but the product file which contains the engine 3D-CAD data and the engine harness geometrical bundle. Here the geometrical bundle product contains all the connectors and other mounting equipment’s, clips and clamps which are electrically defined for the assembly. Sheet metal L-clamp are added in the main context assembly.

Then we need to switch into the electrical harness assembly workbench and Geometrical bundle product file should be electrically defined using the Define Geometrical bundle option before adding any parts into it .

STEP 6 - Adding 4 pole connectors to all fuel injector sensors as well as for the camshaft sensors.4 pole connectors should be added in the geometrically. Connectors can be added again by copy pasting the 1st imported connector. Place the connectors on all the fuel injector sensors and cam-shaft sensors using the manipulation tools like move, smart move, snap tool and also using the compass.

STEP7- Adding other connector like coolant heat sensor, natural position sensor, speed sensor.

Placing the Interconnection connector and L-clamp support .

However, situation of interconnection connectors is not similar to device connectors. Interconnection connectors are not parked with any device but should be pared with the help of clips/clamps/sheet metal brackets etc. possible to the packaging conditions.

Un parked connectors can create following issues-

• Rattling noise
• Physical damage to connectors.
• Uncontrolled harness routing.
• Manual errors during assembly because of undefined parking.

STEP 8- placement of channel in required position on both sides.

STEP 9- Bundle routing from Interconnection connector to 3 P-clamps. Here, we are routing the bundle segment from interconnection connector to 3 P-clamps.

The diameter for this routing path is 12mm and bend radius ratio is assumed to be 1.4.

Adding branch points to 4 cam-shaft sensors.

STEP 10- Routing to the plastic guiding channel Another branch point is added from the interconnection connector at distance. From this branch point, the bundle is routed to the right guiding channel. We have provided fir tree clip in between branch point and guiding channel for the smooth routing.

we can see that the bundle segment inside the guiding channel is created by using pre-made sketch as routing definition. The bundle diameter is assumed to be 10mm.

Similarly, we have done routing for the left side guiding channel.

STEP 11- Adding protective coverings and guiding channels top shell to harness bundle

Here in below figure, we have done with whole wiring harness routing for the Bugatti VI6 Engine. Now, we have to add protective coverings to all bundle segments and top shell of the guiding channel.

STEP 12- Checking bundle continuity

In this step, first we have to make sure that multi-branch able is selected then we have to go in Edit>Search>Advanced>Workbench-Electrical Type-Bundle Segment>Attribute-Fully Connected

By selecting True’ option will show all the connected bundle segments while selecting.

False’ option will show all the non-connected bundle segments.

Here, we have selected for the False option and searched for results. No bundle segments are highlighted found showing that means all the bundle segments are electrically connected.

STEP 13- Creating flatten view of the engine harness geometrical bundle assembly

In this step, for creating flatten view we have to work in Electrical Harness Flattening workbench of Catia V5. We should also make sure that the flattening file is saved in the same folder where other files of harness assembly are saved.

Before creating flatten view, first we have to define flattening parameters. Make sure that selecting ‘Single line’ for bundle segment and Double line for protective covering.

We have extracted the bundle assembly into Engine Harness Flattening Product file and then flattened the file along face of interconnection connector as shown in above figure. At this stage, for clarity, we have been hidden the flattening diagram of the plastic guiding channels from the drawing view.

Create a Drawing File for the flattened harness product.

First, we need to make sure that in the flatten parameter settings bundles and protective coverings have different graphical representation which are,

Bundle Segments - Single line representation

Protective coverings - Double line representation.

Create a new drawing file in the drafting workbench

we are creating new drawing file and defined all the necessary drawing parameters. We have to insert the front view of the Engine Harness Flattening Product file into the Drawing file.

We have to define drawing properties as shown in above figure. it should be noted that in Dress up’ settings 3D wireframe is always ON. If this setting is not selected then the bundle segments won’t be visible on drawing view.

CONCLUSION-

In this project I have successfully routed the wiring harness for the VI6 Engine assembly and the flatten-view drawing was prepared in CATIA V5. Various packaging rules and constraints were considered while routing the harness. After finalizing the wire routing, we can request the corresponding Engine design team to provide additional holes for the mounting of Fir tree clips.