Wiring Harness Routing on V16 Engine

PROJECT -1 : Wiring Harness Routing on V16 Engine

AIM

Route the Wiring harness on V16 Engine in CATA V5.

OBJECTIVES

• Define the connectors ,clips and clamps electrically for the harness bundle routing.
• Develop a Bundle Routing in V16 engine.
• Create a drawing for Routed engine assembly.

THEORY

A wiring harness is a logical arrangement of wires, terminals, and connectors that runs throughout the entire vehicle and transmits data and electrical power, effectively "connecting" a number of different components. Similar to how the circulatory and central nervous systems of the human body transmit energy and information, this network does the same. Wire harnesses are collections of electrical cables used in electrical applications to carry signals. They are a collection of slack wires that have been bundled into a single covering to create a more streamlined system. Many other industries employ these wire harnesses, with the automotive industry being one of the biggest users.

For the optimum performance, automotive wire harnesses employ a wide range of wire harnesses. These harnesses integrate the electrical and electronic device wiring from several devices into a single system. As a result, they support the transfer of signals and the activation of various electrical and electronic equipment. They are made to work successfully in harsh environments and are also used to set up electrical circuits in autos.

BENEFITS OF AUTOMOTIVE WIRING HARNESS

• Reduced installation time

Consider adding numerous wires to your system. Then, think of installing a single device that connects several wires. It goes without saying that installing a single unit is far quicker than installing many units. Additionally, this lessens the possibility of faulty wiring.

• Reduced risk of shorting

The use of wire harnesses reduces the chance of electrical circuit shorts by combining many wires into rigid bundles, making them safer than loose wires.

• Great performance in harsh conditions

The materials used to make automotive wiring harnesses are strong, making the harness strong as well. These bundles are made to function remarkably well in challenging environments and to carry large power loads.

• Improved fuel efficiency

Every vehicle's ability to increase fuel efficiency is greatly helped by wiring harnesses.

• Performance in hybrid cars

Automotive wire harnesses are the ideal choices for hybrid cars since they offer exceptional performance in challenging settings as well. This indicates that these harnesses can handle electrical loads, withstand high heat, and electromagnetic noise while still transmitting large currents under challenging circumstances.

APPLICATIONS OF AUTOMOTIVE WIRING HARNESS

• Two wheelers, three wheelers, cars, utility vehicles, and commercial vehicles.
• Electrical and geometrical requirements of automobiles, and are embedded in the body, engine, and chassis of vehicles.
• Body wiring harnesses are embedded into dashboards, door locks, power windows, and interior electrical components.
• Engine wiring harnesses embed into speed sensors, lock breaking systems, cruise control systems, and fuel injection systems.
• Chassis wiring comprise of the front, rear and main harnesses.

Electrically Defined 1563681-1 Connector

Electrically Defined 173090-2 Connector

Electrically Defined 1743572-2 Connector

Electrically Defined Furr tree clip

Electrically Defined Bottom channel

Top channel

Assembly design of top and bottom channel

Bundle Routing For electrical connections

Connector Routing of V16 Engine

Routing of Engine left channel opend

Routing of Engine right channel opend

Routing of Engine left channel closed

Routing of Engine right channel closed

Application of corrugated tubes in the bundle

Developed Routing model for V16 Engine

Flattening product for routing

Cad drawing For Flattening Bundle-connector Routing

Cad drawing For Routing in V16 Engine

Steps followed

• Defined connector, Bundle connection point and connector-connection point for 1563681-1 Connector.
• Defined connector, Bundle connection point and connector-connection point for 173090-2 Connector.
• Defined connector, Bundle connection point and connector-connection point for 1743572-2 Connector.
• Defined Bundle entry and exit point for Furr tree clip.
• Defined Channel curve and Bundle exit point for bottom channel.
• Assembly design of bottom and top channels has created.
• Imported V16 engine in to the context assembly.
• Created new bundle product file in context assembly.
• Imported all the connectors, clips and channels required for the bundle assembly.
• Connector assembly is performed in assembly design using smart move option.
• Furr tree clips are provides in betwwen the connectors for the better routing.
• Defined the bundle assembly in to the Electrical harness assembly.
• Defined branch definition.
• Conneted the electrically defined parts using route definition.
• Created brach points in betwwen the connectors using add branch point option.
• Bend radius ratio is set as 1.4.
• Should ensure that the Bend radius should be less than computed bend radius.
• Automatic offset connection is enabled.
• Flattenging of bundle connector is performed in Electrical flattening workbench.
• Created the drawing for bundle- Connector and Engine routing.

CONCLUSIONS

• Electrical connections for all the components are done successfully.
• Electrical Harness Routing for V16 Engine has developed successfully.
• Flattening of bundle-connector is performed successfully.
• CAD Drawing Has created from developed Engine-routing system

Project Submitted by

Manu Mohan V