Project 1

 AIM

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

OBJECTIVE

   The objective of the project is to route the wiring harness on given bugatt V16 engine and prepare flatten view drawing in CATIA V5. All types of packaging. Also industry best proactes should be demontrated in design. All the necessary detail like clearance, clipping/ clamping selection ,harness fixing requirement harness continvity should be provide in order to design wiring harness.

• The above figure show the 16 value bugatti engine whech 8 cylinder are placed on the right side and 8 cylinder are place on the left side.
• There are total 16 injection where 8 injection are used for 8 cylinder on right side and 8 injection are used for another 8 cylinder on lest side.
• Also there are 4-cam-shaft sensors so there are threr are total 20 sensors that we have to connected electrically.
• Generally 4-pole connectors are used for fule injectors of the engine.
• The engine will also have an interconnection connector which will connect the engine to other part of the vechicle. We will be using a-12-pole electrical connector with a mounting clip feature as an interconnection connector.
• The plastic guiding channel used in the harness bemade of a material that can with stand at least 150 degree celcius.
• The bend ratio for the all bundle segment should be 14.

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.

Creating Context Assembly

 4-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.

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

   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.

Adding sheet metal bracket

   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 bolt 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.

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 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 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.

Adding protective coverings and guiding channels top shell to harness bundle

   Here in below figure, 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 shell of the guiding channel.

Creating flatten view of the engine harness geometrical bundle 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.

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.