Project 1

Aim

Route the Wiring harness on Given Engine and Prepare flatten view drawing in CATIA V5. Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required.

first we have to understand the wiring harness and packing rules

WIRING HARNESS OR CABLE HARNESS:

A cable harness, also known as a wire harness, wiring harness, cable assembly, wiring assembly, or wiring loom, is an assembly of electrical cables or wires which transmit signals or electrical power. The cables are bound together by a durable material such as rubber, vinyl, electrical tape, conduit, a weave of extruded string, or a combination

Cable harnesses are usually designed according to geometric and electrical requirements. A diagram is then provided (either on paper or on a monitor) for the assembly preparation and assembly.

The wires are first cut to the desired length, usually using a special wire-cutting machine. The wires may also be printed on by a special machine during the cutting process or on a separate machine. After this, the ends of the wires are stripped to expose the metal (or core) of the wires, which are fitted with any required terminals or connector housings. The cables are assembled and clamped together on a special workbench, or onto a pinboard (assembly board), according to design specifications, to form the cable harness. After fitting any protective sleeves, conduit, or extruded yarn, the harness is either fitted directly in the vehicle or shipped.

PACKAGING RULES:

• Wiring harness routing shall provide ease in manufacturing, accessibility, easy removal, and easy maintenance of attached equipment and wiring harnesses.
• Routing through small structural holes and openings shall be avoided, minimizing 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 handheld 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 the bolted joints. It may damage the harness or puncture the harness. Keep harnesses 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 the clip and the branching point is to be 25 mm.

Min distance between two branch breakouts should be 50 mm.Routing_process

We can download the 3D data which used to route the routing from te.com or we can use the CAD fiels which given for the Engine_routing 

After downloading the connectors we have to identify it as Electrical part and use it for routing purpose

connectors used for routing :

c-173090

c-282080

c-4536689

Provide clips/clamps as per requirement.

Make sure that there is no falling case while designing the wire harness. Additional clips/clamps may be used to avoid falling cases.

Avoid routing over the bolt and bolted joints to avoid harness puncture.

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

Follow the clearance distance and keep away the harness from heat generation components.

The connections should be connected properly to the connectors of 16 cylinders properly 

we acn use the separate bundle point for the connectors to avoid multiple segments ploting on a single bundle

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

the flattening properties has to be choosen propely from a certain axis to avoid un necessary constraints 

we can use the bend method to provied needed level of dimensions for drawing 

 The connectors

 Two pole connector

4-pole connector

12-pole connector

Supporting parts

Fur_tree_clip

P-clamp

L-bend

Engine_routing

After make the given parts as Electrical and supporting parts we can route the engine 

after bundle connected with required connectors we can use the protective covering by creating COT_tubes files and add it to the bundle

Flatening

after routing process finishes we can flattening the Bundle segment from Electrical flattening

for flatening we have to create the flatening parameters first after that we can use the command which use to flaten the bundle segment then we can extract the bundle from Engine_routing file and use the command flattening and we can use the needed bend and rotate command to rotate the bundle

Drawing process

for the drawing process we have to create the new drawing file and select the default ISO sheet and choose the front view to import the flatening product to the drawing sheet

after that we can add the title block to the drawing