Project 1

Engine:

Aim:

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

Objective :

• The objective of a project is to route the wiring harness on the given Engine and prepare flatten view drawing in CATIA V5.
• All types of packaging rules haves to be a considered while routing the harness.
• Also, the Industry best practices should be demonstrated in design.
• All the necessary details like a clearance, clipping / clamping selection, harness fixing requirements, harness continuity should be a provided in the order to design wiring harness.

Wiring Harness Routing OF The Engine:

• Engine is taken to a route the wiring harness. The engine modeller will provide the dummy connectors at the locations.
• First check for all the connector and the sensor locations. The present engine has a 8 connector location on each side and 2 sensors at the each side.
• The clips, clamps and channels are used to route the harness with optimal solution.
• Also there are 4 cam -shaft sensors, so there are total 20's sensors that we have to connected electrically.
• Generally, 4-pole connectors are used for the fuel injectors of the engine.
• The engine will also have an interconnection connector whichs will connect the engine to the other parts of the vehicle. We will be using an 12-pole electrical connector with a mounting clip feature as a interconnection connector.
• The plastic guiding channel used in these harness should bemade of a material that can withstand at least 150-degree Celcius.
• The bend ratio for the all bundles segmet should be 1.4

Assumption :

• Provide clips/clamps as per the requirement.
• Make sure that there is no any fauling case while the designing of wire harness. Additional clips/clamps may be used to avoid fauling case.
• Give additional slack if needed. 5-10% slack is sufficient.
• Avoid routing over the bolt and bolted joints to a avoid harness puncture.
• Avoid routing on the sharp edges or else provide protection over a harness.
• Follow the clearance distance and to keep away the harness from heat generation components.
• Protection should be a provided as needed according to a surrounding temperature.
• Avoid direct support for a harness on fuel lines routed in a engine.
• Use a plastic guiding channels if needs.
• Branch length should have be greater than 50mm.
• Minimum distance between the two branch points should have be at least 50mm.
• Minimum distance between the clip and branch point should have be at least 25mm.
• Avoid too many sheet metal brackets on engine. Try to use available threaded bosses on a engine or demand for it.
• The wiring harness should be easy to the assemble and easy to access.
• While using dummy connectors, ensure that whatever the positions you are defining that are the practical. Bundle diameters and another placements can be defined properly for wire harness routing.
• If the packaging area is too tight and there are many packaging constraints then we can think of the creating harness channel which can be used to the route and protect a wire harness effectively.
• Creating Connectivity of Assembly

• A Context Assembly for the Engine Harness has created which will work's the main assembly as shown in above figure.
• A Context Assembly will contains Engine Assembly data for Bugatti V16 Engine and the Engine Harness Geometrical Bundle Assembly.
• If any sheet metal bracket will requires then they are added in the context assembly.

define 4-pole connector for electrically

• Here, according to the requirement we are using 'C-1563689' which is an 4-pole connector. This CAD-data is downloaded from the te.com. Now, to define a connector electrically we should defines the geometrical parameters like bundle connection point and the connector connection points in Electrical Part Design workbench for the downloaded connector.

connectors to the all 16 fuel injector sensors and the 4 cam-shaft sensors

• In this step, we are placing connector's to fuel injector sensors and cam-shaft sensors. So we will requires total 20 connectors which have to be added in an Engine Harness Geometrical Bundles Assembly. We have to use manipulation tools along with the compass, snap and smart move features to locate all the 20 connector's at their desired the locations.

IMAGES OF ELECTRICAL HARNESS:

• The connectors in a assembly should be electrically defined and its placed in the appropriated position on the engine surface . After positioning the connectors place in the supporting mounting clips in the engine to acheives the proper routing without fouling of bundle with the surrounding parts . After achieving the route the harness in the geometric bundle , make sure the bundle segments do not clash with the surronding parts . Flatten the geometric bundle after finalised the geometric bundles, make sure for the bundles connectivity in the wiring harness.

bundle continuity:

• In this step, first we have to make sure these multi-branchable is selected then we have to go in Edit.>Search.>Advanced.>Workbench-Electrical>Type-Bundle Segment.>Attribute-Fully Connected
• By selecting the 'True' option will show all the connected bundle segment's while selecting the 'False' option will show all the non-connected bundle segments..
• Here, we have selected the 'True' option and searched for results. All bundle segments are highlighted found showing that all bundle segments are electrically

Flatten view of the engine harness geometrical bundle assembly

• In this step, for creating flatten view we have the work in Electrical Harness Flattening workbench of the Catia V5. We should also make sure that the flattening file is the saved in same folder where other files of harness assembly are saved.
• Before creating flatten the view, first we have to define flattening parameters . Make sure that the selecting 'Single line' for bundle segment and the 'Double' line for protective covering.

• We have extracted the bundle assembly into the 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 flattening the diagram of the plastic guiding channels from the drawing view.
• In the above figure, we are creating new drawing file and the defined all the necessary drawing parameters. We have to insert the front view of the Engine Harness Flattening Product file into the Drawing file.
• drafting...

Conclusion :

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