Project 1

AIM:

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

INTRODUCTION

         A wire harness, also commonly referred to as a wiring harness, is an exterior sheat used to cover some types of electronic wires. Generally, wiring harnesses are made of thermoplastic or thermoset materials that can help protect the cables from the environment.

     An engine wiring harness is constricted wires, cables, terminals, and connectors controlling a vehicle’s electrical system. It relays electrical power and control information to components such as batteries, alternators,fuel injectors, fuses, audio systems,blower motors, fuel injectors, and computers. Wire harness companies customize it for every location, application, and design it interconnects. Also known as a cable harness, it is more than just a collection of multiple wires put together.

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 sensors.

OBJECTIVES:

     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.

                                         FIG:- BUGATTI VEYRON V16 ENGINE

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

ASSUMPTION:

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.

STEP1:-CREATING CONTEXT ASSEMBLY

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

STEP:-2 DEFINE FOUR-POLE CONNECTOR ELECTRICALLY

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

STEP :-3 ADDING CONNECTORS TO THE INJECTORS AND CAM SENSOR

In this step, we are placing connectors to fuel injector sensors and cam-shaft sensors. 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.

STEP:-4 ADDING L-CLIP FOR FIXING INTERCONNECTION CONNECTOR

STEP:-5 DEFINE THE INTERCONNECTION CONNECTOR ELECTRICALLY

   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. 

Here we have fixing the interconnection connector to the L-clip on the proper position.

STEP:-6 ADDING P CLAMPS

 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. 

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

STEP:-7 MOUNTING 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 560mm 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.
• Electrically defined the plastic guiding channel shown in below the picture.

Here we have fixing the bottom of the plastic guiding chennel on the v16 engine shown in below the picture.

• 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.

STEP:-8 ROUTING THE BUNDLE FROM INTERCONNECTION TO P CLAMPS

• Here We are routing the bundle segment interconnection connector from 3 p clamps.
• The bundle diameter is take it 10mm to routing path and bend radius to be 1.4

STEP:-9 ADD BRANCHABLE FOR CAM SENSOR

Adding branch point to the bundle segment at distance of 0.5ratio from P-clamp as shown in below figure.

STEP:-9 ROUTING THE BUNDLE TO THE PLASTIC CHANNEL

            

• In above figure, we can see that the bundle segment inside the guiding channel is created by using pre-made sketch as routing definition. 

STEP:-10 ADDING PRANCHING POINT IN THE BUNDLE SEGMENT TO THE GUINDING CHANNEL

        Here, from the entry side of the guiding channel, we have created first branch point at 105mm and then subsequently created six branch points at 65mm as shown in below figure.

 

 In above figure, we are routed bundle segment from the newly created branch points to the 8 fuel-injector connectors. The bundle diameter is assumed to be 5mm to the both right and left side of the engine.

STEP:-11 ADDING PROTECTIVE COVERING AND TOP PLASTIC CHANNEL

         Here, 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 of the guiding channel.

STEP:-12 CHECKING BUNDLE CONNECTIVITY

• In this step, 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.

STEP:-13 CREATING FLATTEN VIEW OF THE 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.
• At this stage, for clarity, we have been hidden the flattening diagram of the plastic guiding channels from the drawing view.

STEP:-14 CREATING FLATTEN VIEW DRAWING

• In above figure, 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.

• In above figure we are inserted the flatten product and then manipulated for required position.

• 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 th bundle segments won't be visible on drawing view.

• In above figure is the background view of the product. 

CONCLUSION

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