Project 1
INTRODUCTION
An automotive wiring harness is an electrical and electronic assembly of several automobile components that plays a vital role in connecting all electronic and electrical components for sensor signals, power supply, and transmitting data for improving vehicle performance, An automotive wiring harness, also known as a wiring loom or cable assembly, is an organized and integrated set of electrical wires, connectors, and terminals that are used to transmit power and signals between various electrical components in a vehicle. Automotive wiring harnesses are typically made up of multiple wires that are bundled together and routed throughout the vehicle's interior and exterior, connecting various electrical components such as the engine, battery, lights, and sensors. The wiring harness is designed to provide a safe, secure, and efficient means of transmitting electrical power and signals while protecting the wiring from heat, vibration, and other environmental damage. Wiring harnesses are typically manufactured using specialized machinery that cuts, strips, and crimps the wires to specific lengths and shapes, and then assembles them into a cohesive harness. The completed harness is then tested to ensure that it meets the required specifications for safety and reliability.
Engine Harness
An engine harness, also known as an engine wiring harness or engine control module (ECM) harness, is a specialized type of automotive wiring harness designed to connect an engine's various electrical components to the vehicle's central computer or engine control module, The engine harness contains a set of wires and connectors that link together the sensors, actuators, ignition coils, fuel injectors, and other electrical components of the engine. These components monitor and control various engine functions, such as fuel injection, ignition timing, and emissions control, The engine harness is typically routed through the vehicle's engine compartment and connected to the engine control module, which uses the data provided by the harness to manage the engine's performance and efficiency. A faulty engine harness can lead to a range of issues, such as misfires, poor fuel economy, and emissions problems. As such, it is important to ensure that the engine harness is properly installed and maintained to ensure optimal engine performance and reliability.
DESIGN METHODOLOGY
download the engine CAD data and required connectors CAD data from the given source, Download the required Connectors from the source and convert the mechanical connectors electrically by using the electrical part design workbench in the below steps, First download the connectors and mounting clip from the given link source, Get into the mechanical part workbench to create required geometrical parameters. Create a connector connection point and the bundle connection point on the required sides of the CAD part, Create an axis system on the connector connection point in such a way that the Y coordinate faces normally to the connector face, the X coordinate faces towards the locking mechanism and Z coordinate facing to the top, Create cavity connection point for connectors having the cavity for mounting clips, Using the geometrical parameters created, Define part as an electrical connector, Define bundle connection point, Define connector connection point, Define cavity connection point, Download and Define the plastic channel electrically, Procedure for electrically defining the Channel, Create bundle entry point and exit point, Create a line curve between the main entry and exit points for creating the multi-branch able using external curve inside the channel, Create 8 bundle entry points on the openings for connecting the injector connectors,Using the geometrical parameters, define the channel electrical using the define mounting equipment option ,Create define bundle entry points using the “define bundle connection point option.”Create Channel symmetrical assembly and define the symmetry bottom channel electrically using the define mounting equipment option and also create all the required geometrical parameters on it, Context assembly is nothing but the product file which contains the engine 3D-CAD data and the engine harness geometrical bundle. Here the geometrical bundle product contains all the connectors and other mounting pieces of equipment, clips, and clamps which are electrically defined for the assembly. Sheet metal L-clamp are added in the main context assembly The Given V16 engine 3D-CAD model requires a total of 23 connectors to be placed on it and an interconnection connector for the engine wiring harness assy. The connectors used in this engine are as follows 8 numbers connectors are required on the fuel injector sensors on each cylinder head, i.e.; a total of 16 fuel injector sensor connectors are needed. Total 4 numbers of cam-shaft sensor connectors are needed.1 neutral position sensor connector and 1-speed sensor connector on the gearbox housing.1 engine coolant temperature sensor placed at the center of engine Adding 4 pole connectors to all fuel injector sensors as well as for the camshaft sensors 4 pole connectors should be added in the geometrical bundle using copy paste connector or directly import from the catalog created earlier Connectors can be added again by copy-pasting the 1st imported connector Place the connectors on all the fuel injector sensors and cam-shaft sensors using the manipulation tools like move, smart move, snap tool and also using the compass Distance between two clamps on a straight branch should be minimum of 200mm. The minimum branch length should be 50mm Minimum distance between the clip and the nearest branching point should be 25mm. The minimum distance between two straight connection points should be 200mm The minimum distance between two breakout points should be 50mm To limit the number of branches from a single branch point to 4 Avoid routing the wiring harness near the exhaust manifold and its components and also from other unshielded heat sources. If re-routing is not possible then maintain a minimum distance of 200mm Try to avoid the use of too many metal brackets on the engine. Try to use the available threaded bosses on the engine or demand it Enough clamps shall be provided to ensure positive clearance with surroundings and safety of the wiring harness P - Clamps, Fir tree clips, and other clips can be added to the Geometric bundle as they are electrically defined and are part of the Wire harness routing and should be provided with the Wire bundle package Enough slack should be provided to the wiring harness which helps it not to get damaged during the Engine rocking or starting condition The wire harness routing should be done in such a way that it is easy in manufacturing and serviceable The wire routing should be done keeping in mind the cost-effectiveness of the bundle package To avoid the harness routing and clipping in blind zones of the operator during the assembly and the service provide proper slack at end connectors so that there will be no tension on the wire bundle To avoid sharp edges on the sheet metal parts and if it is not possible then provide protection parts to prevent damage to the wire bundle To provide separate branch points for separate connectors to ensure Poka-Yoke Keeping all the above packaging rules we can start the routing of the wire and provide clipping and clamping wherever necessary during the routing process ENGINE with all the components for wiring harness routing
assembly
wiring harness connector continuity check
total assembly
The following means can be used to protect the wiring harness in high-temperature zones
Use of Corrugated tubes
They are of two types Slit and Non-slit Cot tubes
Corrugated flexible tubes also known as COT tubes / convoluted conduits have a wide range of applications in automotive industries.
Corrugated tubes are made from plastic and they are flexible.
Polypropylene (PP) for (-) 20 to 100 degree Celsius
Heat Resistant (HR) for (-) 20 to 135 degree Celsius
Flame Retardant (FR) for (-) 20 to 135 degree Celsius (flame retardant)
Polyamide/nylon (PA) for (-) 20 to 180 degree Celsius
Use of breaded tubes (Nylon woven loom) and Silica sleeves –
In case of the corrugated tube is not suitable for very high-temperature zones (especially in the exhaust area), the use of breathed tubes and silica sleeves can be done.
Beaded Tube- is expandable sleeving braided from 8 mils (0.2mm) flame-resistant polyphenylene sulfide (PPS) monofilament fiber, extremely lightweight, resistant to high temperatures (up to 285 degrees Celsius), and virtually impervious to solvents.
Silica Sleeve – it is braided into a strong and flexible sleeve from silica yarns. The thick 560mil (1.5mm) walls of this sleeving provide enhanced thermal protection up to 1800-degree Fahrenheit (982 degree Celsius)
