Project 1

Project 1 :

Aim :

To route the Wiring harness on Given Engine and Prepare flatten view drawing in CATIA V5.Apply Protection coverings as required.Prepare & Submit all necessary reports like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity, Assumptions if any along with CATIA 3D data.

• The given cad model is a 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 be made of a material that can withstand at least 150 degree Celcius.
• The bend ratio for the all bundle segmets should be 1.4.

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.

Steps and procedures :

• A new product file was opened and then the engine cad model was imported.

• The four pole connector was defined electrically.The connector which is used here is 'C-1563689' model.
• The cad model was downloaded from the te website
• Then the connector definition,Bundle connection point and the connector connection point was defined.

• The connector was imported to the engine context and placed in the appropriate positions using the commands like manupulation and smart move.

• A metal sheet was added to the assemby with a connector which was electrically defined was mounted on it.

• The bottom of the guiding channel was imported then electrically defined and the bundle connection point was set and added to the assembly.

• P clamps were electrically defined and mounted to the engine.

• Now all the bundle components are assembled to the engine and the next is the bundle connection.
• The electrical wiring harness workbench was opened and the bundle connections were made accordingly.

• The protective covering was added to the bundle.

• Here in below figure, we have done with whole wiring harness routing for the Bugatti V16 Engine. Now, we have to add protective coverings to all bundle segments and top shell of the guiding channel.

• To check the bundle connectivity

  first we have to make sure that multi-branchable 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 'True' option and searched for results. All the bundle segments are highlighted found showing that all the bundle segments are electrically connected as shown in below figure.

• Once the bundle continuity is checked the next is the flattening process.
• The flattening workbench was opened and the flattening parameters was set.
• Then it was save to the same file where the engine context was saved.
• Both the files was opened in vertical window and the geomwntrical bundle fie was extracted to the flattening product.
• Then using few commands the flattening product was done.

• The below image shows the final drawing view of the engine harness flatten view.

Conclusion :

• In this way, we have routed wiring harness for the given V16 Engine. Also, prepared flatten view drawing with proper sheet in CATIA V5.