Project 1

project -1

Aim :- To route the wiring harness bundle segment to given v16 engine and apply to different area of topology and mounting harness bundle and check the electrically fitted or not , finally apply flattening and drawing view

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

• 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.
• 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 bemade of a materials that can withstand at least 150 degree Celcius.
• The bend ratio for the all bundle segmets should be 1.4

Assumptions-

• Provide clips/clamps as per requirement.
• Make sure that there is no any fauling case while designing the 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 bolt and bolted joints to avoid harness puncture.
• Avoid routing on sharp edges or else provide protection over the harness.
• Follow the clearance distance and keep away the harness from heat generation components.
• Protection should be provided as needed according to surrounding temperature.
• Avoid direct support for harness on fuel lines routed in the engine.
• Use plastic guiding channels if needed.
• Branch length should be greater than 50mm.
• Minimum distance between two branch points should be at least 50mm.
• Minimum distance between clip and branch point should be at least 25mm.
• Avoid too many sheet metal brackets on the engine. Try to use available threaded bosses on the engine or demand for it.
• The wiring harness should be easy to assemble and easy to access.
• 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.
• 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.

1. Create context Assembly:-

• context assembly which will work on main assembly
• Context assembly which will contain v16 engine data and harness Geometrical bundle assembly
• if any additional sheet metal brackets we can add in context assembly

2. Define 4 Pole connectors :-

• According to fuel injector required the connector is C-1563689-1 this is suitable connector . 4 pole connector given CAD data of te.com and download cad file , define 4 pole connectors are electrically defined , it's means geometrical parameter like Bundle connection point and connector connection point and cavity connection point also defined

3. add the all 4 pole connectors into Fuel injecoters are 16 fuel injectores sensors and cam shaft sensor So we will require total 20 connectors which have to be added in the Engine Harness Geometrical Bundle Assembly. We have to use manipulation tools along with compass, snap and smart move features to locate all the 20 connectors at their desired locations.

4. Now, we have to add sheet metal bracket in order to provide mounting for the interconnection connector. Also, we have to make sure that the bracket is placed inside the context assembly and outside of engine and geometrical bundle assembly. The bracket should be mounted on the existing hole as shown below. This bracket should have locking system in clockwise direction so that it can't be move freely. Herein below figure, rib is performing the locking feature for the bracket. All the design ideas should be discussed with the engine designing team so that there won't be any disturbance for the smooth working of engine in real world application.

5. Mounting the interconnection connector on the sheet metal bracket and mounting the p-clamps for wire harness

Here, a 12 pole connector "C-776438-4" and mounting cavity "C-1924487-2" is together used as interconnection connector. The required cad data is downloaded from te.com. First, we have to define 12 pole connector and mounting cavity electrically as below.

• Mounting cavity is "C-1924487-2" are electrical defined

• 12 pole connector and mounting cavity are electrically connected together in electrical assembly design workbench. mounting L - clamp near smart move and fixe it in 12 pole connector and mouting clip

• Now, we have to mount that electrically connected interconnection connector and cavity on sheet metal bracket as shown in above figure.
• We have to mount 3 P-clamps also on the existing bolts holes of the engine so before that we have to define P-clamp electrically with geometrical parameters, entry and exit point on both left and right side of the P-clamp as shown in below figure.

shown in below engine mouting area:-

• Here, we have mounted 3 P-clamps on the existing bolts of the engine for the wire harness routing as shown in above figure.

• In above figure, we have mounted furr tree clip also for the smooth path to wiring harness routing towards guiding channel on both right and left side.

6. Mounting of a plastic guiding channel

We have to add now plastic guiding channel because Bugatti V16 engine has 8 injectors on right side and 8 injectors on left side which are very close to each other. Hence plastic guiding channel is best option for proper and easy routing of the wiring harness. It will reduce the complex wiring harness routing. We will require two different guiding channel for both right and left side of the engine. Now, before placing guiding channel, we have to define geometrical parameters of guiding channel as below.

• In above figure, we have created point 1 at entry face and another point at endpoint at 549mm distance.
• Now, join that both points and create a line which will be later used for routing the wire harness bundle inside the guiding channel.
• Above figure shows for the left side guiding channel and same process will be repeated for the right side channel.

• Now in above figure, we have created bundle entry points for the eight connectors, one bundle entry point at channel entry face and defined guiding channel electrically as equipment.

• After electrically define of guiding channel, we have located guiding channel at desired place as shown in above figure.
• Here, we have used different commands like manipulation, snap, smart move, compass etc. for placing of guiding channel.
• Now at this stage, we have just located bottom of the guiding channel.

• In above figure, whole assembly is ready for the routing.
• All 20 connectors, 3 P-clamps, 1 Interconnection connector, 2 furr tree clips and 2 plastic guiding channels are mounted.

7. 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