Project 1

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.

ENGINE WIRING HARNESS ROUTING

The above figure shows the given V16 engine cad data .Here routing the wiring harness for the following electrical components attached to the engine.

• fuel injector for each cylinder we have 16 cylinder engine
• camshaft sensors on each engine block (4 camshaft sensor )
• Engine coolant sensor at the centre of the engine between the two blocks
• Engine oil temperature and oil pressure sensor fitted at the oil sump of the engine on both engine cylinder blocks
• sensors for sense neutral positon of the transmission assembly and measure the vehicle speed
• Interconnection connector to connect engine harness system to vehicle harness system.

Harness mounting and routing management required to provide proper packaging of the wiring harness.it also deals with clearance management and manufacturability

• P-clamps to provide positive clamping and proper clearance management for the routing
• Mounting clips for connector mounting
• Guiding channels provide thermal protection in high temperature zones .
• Corrugated tubes used to protect the wiring harness from hazardous liquids and temperature

Next create a new product in assembly workbench named as assembly wiring harness contex .it is the top level product file inside this product file created geometrical bundle and wire harness electrical bundle.Given V16 engine cad data added inside this contex assembly.

Geometrical bundle contains all of the harness components i.e connectors ,clip, gromets and actual physical bundle segments and branches.All the components should be defined electrically .

Download the 3d data of required connectors and mountings from the site www.te.com

Step 1 : Define all Electrical parts

here 16 nos 4 pole connector used for fuel injectors model no : 1563869

4 nos 2 pole connectors used for camshaft sensor no: 173090

1 no 2 pole connector used for Engine coolant sensor no: 173090

2 nos 2 pole connector used for Engine oil temperature and oil pressure sensor no: 173090

1 no 12 pole connector for inter connection no: 776438

All connectors cad files are downloaded from www.te.com & defined as electrical connector

inter connection no: 776438

Cavity clip

4 pole connector used for fuel injectors model no : 1563869

2 pole connectors no: 173090

P Clamp

Fir tree clip

Channel bottom

Step 2 : Assemble the connector and clips

Create a new product file & assemble the connector to respective area and also clips for suitable position

Inter connector is electrically connected with cavity clip

Step 3 : start the bundle segment

Step 4 : check the bundle Continuity

Bundle fully connected

No false connection

Step 5 : Define Corrugated tube on bundle

WIRING HARNESS FLATTENING

Drawing - WIRING HARNESS FLATTENING

CONCLUTION

In this way, we have routed wiring harness for the V16 Engine. Also, prepared flatten view drawing with proper sheet in CATIA V5