Challenge

Project 1

GGuruprasad Joshi19 Apr 2023

Objective:

The objective of the project is to route the wiring harness on given Bugatti 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.

The above figure shows the 16 valve Engine where 8 cylinders are placed on the right side and 8 cylinders are placed on the left side.
There are total 16 injectors where 8 injectors are used for 8 cylinders on right side and 8 injectors are used for another 8 cylinders on left side.
Also there are 4 cam-shaft sensors, so there are total 20 sensors that we have to connected electrically.
Generally, 4-pole connectors are used for fuel injectors of the engine.
The engine will also have an interconnection connector which will connect the engine to other parts of the vehicle. We will be using a 12-pole electrical connector with a mounting clip feature as an interconnection connector.
The plastic guiding channel used in this harness should bemade of a material that can withstand at least 150 degree Celcius.
The bend ratio for the all bundle segmets should be 1.5
16 valve Bugatti Engine.

Step 1: Creating Context Assembly

A Context Assembly for Engine Harness has created which will work as the main assembly as shown in above figure.
A Context Assembly will contain Engine Assembly data for Bugatti V16 Engine and Engine Harness Geometrical Bundle Assembly.
If any sheet metal bracket will require then they are added in the context assembly.

4 POLE CONNECTOR

3 POLE CONNECTOR

12POLE CONNECTOR & CAVITY CLIP

2 POLE CONNECTOR

P_Clamp

L_CLIP

Step 2- To define all connector electrically.

We have to define all the connector that is 2 pole, 3pole, 4 pole and 12 pole interconnection connector as an electrical part by define as connector connection point & bundle connection point.

Also define the clip & channels that is needed as an electrical part.

Step 3- Adding connectors to the all 16 fuel injector sensors and 4 cam-shaft sensors.

In this step, we are placing connectors to fuel injector sensors and camshaft sensors. So we will require total 20 connectors which have to be added in the Engine Harness Geometrical Bundle Assembly. We have to use manipulation tools along with compass, snap & smart move features to locate all the 20 connectors at their desired locations.

Step 4:- Adding sheet metal bracket

Step 5:- Mounting the interconnection connector on the sheet metal bracket and mounting the p-clamps for wire harness

Step 6:- Mounting of a plastic guiding channel

Step 7:- Bundle routing from Interconnection connector to 3 P-clamps

Step 8:- Routing to the plastic guiding channel

Step 10:- Adding branch points to bundle segment inside the guiding channel

Routed cable assembly without protecting cover-

Step 11:- Adding protective coverings and guiding channels top shell to harness bundle

Routed cable assembly with protecting cover-

In this step, first we have to make sure that multi-branchable is selected then we have to go -

Edit>Search>Advanced>Workbench-Electrical>Type-Bundle Segment>Attribute-Fully Connected

By selecting 'True' option will show all the connected bundle segments while selecting 'False' option will show all the non-connected bundle segments.
Here, we have selected for the 'True' option and searched for results. All the bundle segments are highlighted found showing that all the bundle segments are electrically connected