Project 1

ENGINE WIRING HARNESS ASSEMBLY

OBJECTIVES:

To route the wiring harness for the given engine. Apply the all Packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required.

INTRODUCTION:

The automotive wiring harness is referred to as the central nervous system in the vehicle. It mainly consists of an electrical harness and the mechanical harness in the design. The current project is focused on the mechanical wiring harness and its rules and procedure to be followed while routing in the virtual condition. CATIA V5 electrical workbench is used as the CAD tool for routing the wires in the engine

CONSISTS OF PARTS GIVEN:

• ENGINE
• CONNECTORS
• P CLAMP
• FIRR TREE CLIP
• CHANNEL BOTTOM
• CHANNEL TOP

DEFINING THE ALL CONNECTORS AND SUPPORT COMPONENTS:

DESIGN CRITERIA AND PACKAGING RULES:

• Wiring harness routing shall provide ease in manufacturing, accessibility, easy removal, and easy maintenance of attached equipment and wiring harness.
• Routing through small structural holes and openings shall be avoided, minimize chaffing and handling of the wiring harness during installation.
• Avoid the harness routing and clipping in the Blind zone of the Operator during harness assembly or in service.
• Routing shall offer protection against possible damage through common misuses such as being handhold and temporary support for test equipment.
• Provide additional slack to the harness according to the surroundings and harness bending requirements.
• Ensure the routing meets the clearance requirements with different surrounding parts.
• Avoid routing over the bolts, near to the bolted joints. It may damage the harness or puncture the harness. Keep harness away from panel mounting screws.
• Avoid harness routing near sharp edges, if not possible provide protection to the harness.
• The maximum distance between two clips on a straight branch is 200mm.
• Provide Clips and clamps if the harness is going to bend at multiple locations.
• The use of too many sheet-metal brackets should be avoided.
• The branch length should be more than 50 mm.
• Min distance between clip and branching point to be 25 mm.
• Min distance between two branch breakouts should be 50 mm.

Wiring harness routing: It is the desired path of wiring harness into given vehicle environment by applying set of design rules and industry best practices.

Wiring harness packaging: deals with the fixing/mounting strategy of wiring harness routing to ensure the safe, reliable and durability of wiring harness by applying set of design rules and industry best practices.

PROTECTION TUBES AND INSULATION TAPES:

• Corrugated flexible tubes also known as Cot Tubes / Convoluted Conduits have a wide range of application in automotive industries.
• Corrugated tubes are made from plastic material and they are flexible.
• Theses tubes are used to protect the harness from thermal and physical damage, sometimes to improve harness appearance.
• Insulations are adhesive/non-adhesive tapes and sleeves. They are made from PVC or cotton/polymer material. Cotton tape in high temperature area

BUNDLE CONTINUITY CHECK:

Go to Edit, Select the Search, in search go to Advance. In Advance, in workbench select the Electrical, in Type select the Bundle Segment, in Attribute select the Fully Connected option.

WIRING HARNESS FLATENING:

This helps to create the 2D drawing of the wiring harness. Switch to Electrical Harness Flattening workbench, which is located in Equipment & systems and Electrical harness discipline.

Wiring Harness 2D drawing:

Take a new file and select the drawing type file. Always take the front view

CONCLUSION:

Engine wiring harness is taken as a case study and developed the geometrical bundle assembly without fouling the bundle segments.