Project 1

ANSWER-

Aim- To route the wiring harness on given Engine and flatten view drawing in CATIA V5.

Objective- The objective of the project is to route the wiring harness on given V16 Engine and prepare flatten view drawing in CATIA V5. All types of packaging rules have to be considered while routing the harness. Also, Industry best practices should be demonstrated in design. All the necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design wiring harness.

Assumptions-

1. Provide clips/clamps as per requirement.
2. Make sure that there is no any fauling case while designing the wire harness. Additional clips/clamps may be used to avoid fauling case.
3. Give additional slack if needed. 5-10% slack is sufficient.
4. Avoid routing over bolt and bolted joints to avoid harness puncture.
5. Avoid routing on sharp edges or else provide protection over the harness.
6. Follow the clearance distance and keep away the harness from heat generation components.
7. Protection should be provided as needed according to surrounding temperature.
8. Avoid direct support for harness on fuel lines routed in the engine.
9. Use plastic guiding channels if needed.
10. Branch length should be greater than 50mm.
11. Minimum distance between two branch points should be at least 50mm.
12. Minimum distance between clip and branch point should be at least 25mm.
13. Avoid too many sheet metal brackets on the engine. Try to use available threaded bosses on the engine or demand for it.
14. The wiring harness should be easy to assemble and easy to access.
15. While using dummy connectors, ensure that whatever positions you are defining that are practical. Bundle diameters and another placements can be defined properly for the wire harness routing.
16. If the packaging area is too tight and there are many packaging constraints then we can think of creating harness channel which can be used to route and protect the wire harness effectively.

CONNECTOR-

Geomentrical Parameters Definition

It's mandatory to create geomentrical parameters such as points and coordinating system in given comoponent to define connection points.

conditions -

Y axis should be in the mating direction

x axis should be in the locking mechanism direction

z axis should be in the direction towards top surface

Defining the connector to create connection points,

To create connection points we should have a electrical equipment like connectors, we should define the part or 3d object as an electrical device.

Connection Point definition-

Bundle Connection point-

This is the point where bundle segment or wire point end when get routed to a connector. This point is known as Bundle Connection Point. At the time of defining bundle connection point, the number of terminals and a face is also provided as an input data.

Connector Connection point:

A connection point is a point in an electrical connector where a cable begins or ends. Electrical connectors are required to have at least one connection point with the route type set to Electrical. This defines the part as an electrical connector and provides information about the route.

This point also used to make an assembly with other systems. This willl be defined by geomentrical parameters that we have already created.

• In Connector connection axis system, we have to always ensure that y-axis should be alwyas in the direction of mating axis of all the connectors.
• And x-axis should be in the diretion of locking mechanism and z-axis should be left-right side of the connector according to the orientation.

P CLAMP

FURR TTREE CLAMP-

The harness context assembly:

This is the top_level product file that contains the harness geometrical bundle/assembly and the wire harness electrical bundle.

Geomentrical Bundle:

This sublevel product file is the wire harness product that contains all of the harness components i.e clips , supports, Connectors, splices,annotations and actual physical bunsle segments and branches.

Electriacl Bundle:

This sub level product file contains all of the electrical circuit information.

GEOMRNTRICAL BUNDLE -

Toolbar to Define geomentrical bundle-

By using the creation tool bar the product file can changed the geomentrical bundle, which is electrical product. It can be defined by a symbol which will be added to the product file.

MULTI BRANCHING-

PROTECTIVE COVERING-

It's developed to protect the wiring bundles which are used in routing. As a protection cover which ensures safety of bundle from sharp edges, high temperature, dust and water. It can be selected by different factors such surrounding parts and environment. Moreover, It will be selected by either cotton or polymer and pvc.

corrugated tubes,Convolutes, Sleeves and many other types of coverings are used to protect the wiring harness.

Analysised the bundle segment continuity-

EXTRACTING THE HARNESS ASSEMBLY AND FLATTEN

CONCLUSION:

In this project i have successfully routed the wiring harness. Various packaging rules and constraints were considered while routing the harness. After finalizing the wire routing, we can request the corresponding Engine design team to provide additional holes for the mounting of design tree clips.