Project 1

                                                           Project 1

AIM:

          Route the wiring harness for the Bugatti V16 Engine assembly and prepare a flatten-view drawing in CATIA V5.

OBJECTIVE: 

                   The objective of this project is to route the wiring harness and prepare the flatten-view drawing for the Bugatti V16 engine. All types of packaging rules and constraints have to be considered while routing the harness. Industry best practices should be implemented in the harness design. All necessary details like clearance/ clamping selection, harness fixing requirements, and harness continuity should be provided in order to design the wiring harness.

Figure 1: Bugatti V16 Engine for which a wiring harness has to be designed.

BACKGROUND, TECHNICAL SPECIFICATIONS, & ASSUMPTIONS:

                                                                                                      The wiring harness packaging rules and the industry best practices that have been followed to complete this project are as follows:-

1. Provide additional slack if needed according to the surrounding and harness bending requirement. Generally, slack between 5-10% is sufficient.

2. It should be made sure that there is no case of fouling while designing the wiring harness in CAD software. Additional clips/ clamps may be used to avoid fouling.

3. Avoid routing over bolts, bolted joints, or screwed joints to avoid harness puncture.

4. Avoid harness routing near sharp edges or else provide protection over the harness.

5. Enough mounting equipment such as clips and clamps should be provided. 

6. Keep away from heat generation components and follow clearance distance.

7. Avoid direct support for harnesses on fuel lines routed in the engine.

8. Avoid too many sheet metal brackets on the engine. Try to use available threaded bosses on the engine or demand for it.

9. Use plastic guiding channels if needed.

10. Branch Length should be greater than 50mm.

11. The minimum distance between Clip to the branch point should be at least 25 mm.

12. The minimum distance between two branch points should be at least 50mm.

13. Protection should be provided as needed according to the surrounding temperature.

14. The wiring harness should be easy to assemble and easy to access.

 

The given Bugatti V16 Engine has 16 fuel injector sensors and 4 cam-shaft sensors. In total, we have 20 sensors that have to be connected electrically. Generally, 4-pole connectors are used for fuel injectors. Therefore, for the simplification of this project, we will be using the same four-pole connector for all 20 sensors. 

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 be made of a material that can stand at least 150 degrees Celcius.

The bend ratio for all the bundle segments is considered to be 1.4

A p-Clamp suitable for at least 20mm diameter wire is to be used for this project.

CONTENT:

STEP1- Creating context assembly

A context assembly has to be created which will serve as the main assembly for the engine harness. The context assembly will contain the 3D-CAD data for the Bugatti V16 engine and the engine harness geometrical bundle. If any sheet metal brackets are required then they are added in this "ASSY ENGINE HARNESS CONTEXT".

STEP2: Defining the connectors electrically 

1] C-156389-1:

2] C-776438-4:

3] C-282080-1:

4] C-173090-2:

Cavity Clip:

P Clamp:

L-Clip:

Bottom Channel L-Side:

Channel Top L-Side:

Bottom Channel R-Side:

Channel Top R-Side:

Routing:

Continuity Check:

Flatten Product:

Drawing:

Final Product Images: