Project 1

Aim- To route the wiring harness of Engine model, protection covering and prepare flatten view drawing in CATIA V5.

Objective- Objective of this project is to route the wiring, protection covering and prepare flatten-view drawing for the given V16 engine model and considering all types of packaging rules constraints while routing the wiring harness .All necessary detsils like clearance/clamping selection,harness fixing requirements,harness continuity should be provided in order to design the wiring harness.

Wiring hamess 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 hamess 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.

The given engine model has 16 fuel injector sensors and 4 cam-shaft sensors that is a total opf 20 sensors.We used 4 pole connectors for fuel injector sensors and for cam-shaft sensors also.

The engine will also have an interconnection connector which will connect the engine to other parts of the vehicle.We used 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 withstand atleast 150 deg celcius.

A context assembly has to be created which will serve as the main assembly for engine harness. The context assembly will contain the 3D-CAD data for the 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:-

The 4-pole connector used for this harness assembly is "C-156389-1". The 3D CAD data for this connector was downloaded from TE.com. To define the connector electrically we should define the geometrical parameters, bundle connection point, and the connector-connection point for the downloaded connector.Similarly we can use C-776438 connector to define those connectors are electicaly

Step3-Adding connectors to all 16 fuel injectors sensor :-

All the connectors have to be added inside the Engine harness geometrical bundle assembly. Manipulation tools along with a compass, snap, and smart move features should be used to locate all the 16 connectors in their desired locations. All the connectors are shown in red for clarity.

First, connectors are located for the first 8-fuel injector sensors which are on the left side of the engine. At last, the remaining 8 connectors are added to the 8 fuel-injectors on the right side of the engine.

Sheet-metal bracket for mounting interconnection connector:-

A sheet -metal bracket has to be created in order to provide mounting for the interconnection connector. We have to make sure that the bracket is placed inside the context assembly outside the engine and harness geometrical bundle assembly. The bracket can be mounted on the existing bolt located as shown below. It has to be made sure that in the real-world application if we are using any existing bolts or screws then the design idea has to be discussed and passed by the engine design engineering team in order to make sure the proper functioning of the engine. This bracket should have a locking feature in the clockwise-direction so it does not rotate freely. The current engine design has a rib feature as shown below which can be used to our advantage as a locking feature. The edge of the bracket will sit on the rib thus locking the bracket in place.

Defining the Interconnection connector and mounting clip electrically and then mounting it on the created bracket. Mounting P clamps for wire harness.

A 12-pole "C-776438-4" connector and mounting cavity "C-1924487-2" is used as an interconnection connector. The 3D-CAD data file for the required connector and the cavity is downloaded from TE.com. Both the connector and the cavity are electrically defined and mounted on the sheet-metal bracket.

The below figure also shows a P-clamp mounted the existing bolt of the engine. The P-clamp is Hellermann Tyton - 211-60129. This P-clamp is good for the maximum diameter of 20.5 mm. Before mounting the P clamps we have to define them electrically. To do so we have to define geometrical parameters and bundle entry and exit points from both left and right side of the P clamp.

A total of 2 P-clamps are used for this wiring harness. They are all mounted on the periphery of the casting on the already existing bolts.And also we use the furr_clip. Before mounting we have to define them electrically.

Plastic Guiding Channel

The V16 engine has 8 fuel injectors on the left side and 8 fuel injectors on the right side of the engine. All these fuel injector sensors are located very close to each other. So, the best way to route the wires around them is by using a plastic guiding channel as they will help us organize all the wires very precisely and will reduce complex wiring harness routing. To mount the plastic guiding channels we would need some mounting provisions. The engine design team can be consulted and asked to provide mounting threaded holes or threaded bosses.

There will be two different plastic guiding channels for this engine. One for the left and theother for the right side of the engine. It has to bemade sure that proper clearance (at least 50mm) is provided between the plastic channel andthe exhaust pipes. The total thickness of thethese channels is 25 mm.

The plastic guiding channel will be a two-piece molded plastic that will protect the wiring harness from surrounding high temperatures, wear and tear while providing nice aesthetics to the engine.

Locating the Guiding channel:-

Use manipulation, compass, snap and smart move commands to locate and move the guiding channels in place as shown below. These channels are added inside the engine harness geometrical bundle. At this stage, we will only add the bottom part of the left and right guiding channels.

Engine with all mounting and guiding provisions:-

The image below shows all 16 connectors ,2 plastic guiding channel ,2 p-clamps,2 furr_clips and interconnection connector mounted on the sheet -metal bracket.

Bundle routing from interconection connector to 2 p_clamps :-

At this stage,we are not using the exact value for bundle diameter(15mm).We will assign the bundle diameter value at a later stage .The bend ratio is assumed to be 1.4

Routing to the guiding channel:-

Another branch point is added at 55mm from the interconnection connector. From this branch point, the bundle is routed to the right side guiding channel. It can be noticed that there is no need of any additional mounting provisions for this bundle segment as the bundle path is practical and completely possible in the real world situation.

Checking Bubdle Continuity:-

First, we have to make sure that multi branchable is selected and then we have to go in WORKBENCH>TYPE-BUNDLE

EDIT>SEARCH>ADVANCED>ELECTRICAL

SEGMENT>ATTRIBUTE-FULLY CONNECTED

Selecting the "TRUE" option will show all the connected bundle segments while the selecting "FALSE" will show all the non-connected bundle segments.

For now, we will select "TRUE" and search for results. All the bundle segments are highlighted and found showing that all the bundle segments are electrically connected.

Adding protection covering :-

Wiring harness flattening:_

Harness drawing:-