Project 1

WEEK # 11 Project-1

Route the Wiring harness on Given Engine and Prepare to flatten the 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.

Available connector 3D data can be used, or you can download the connectors from www.te.com

Prepare & Submit all necessary reports like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity, and Assumptions, along with CATIA 3D data.

Engine cad data is to be downloaded from www.grabcad.com

Engine file

or Engine file Lite version - for systems having low RAM

CAD Files

the development of the Engine wiring harness is to route the wiring harness on the given Bugatti V16 Engine and prepare to flatten the 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, and harness continuity should be provided to design the wiring harness.

1. The above figure shows the 16-valve Bugatti Engine where 8 cylinders are placed on the right side and 8 cylinders are placed on the left side.
2. There are a total of 16 injectors where 8 injectors are used for 8 cylinders on the right side and 8 injectors are used for another 8 cylinders on the left side.
3. Also, there are 4 cam-shaft sensors, so there are a total of 20 sensors that we have to connect electrically.
4. Generally, 4-pole connectors are used for fuel injectors of the engine.
5. The engine will also have an interconnection connector which will connect the machine to other parts of the vehicle. We will use a 12-pole electrical connector with a mounting clip feature as an interconnection connector.
6. The plastic guiding channel used in this harness should be made of a material that can withstand at least 150 degrees Celcius.
7. The bend ratio for all bundle segments bending ratio should be 1.4

summarize this project

Provide clips/clamps as per requirement.

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

CONTEXT ASSEMBLY CREATIONS

A Context Assembly for the Engine Harness has been created which will work as the main assembly as shown in the 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.

Here, according to the requirement we are using 'C-1563689' which is a 4-pole connector. This CAD data is downloaded from te.com. Now, to define a connector electrically we should define the geometrical parameters like bundle connection point and connector connection point in the Electrical Part Design workbench for the downloaded connector.

Adding connectors to all 16 fuel injector sensors and 4 cam-shaft sensors

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

Adding connectors to all 16 fuel injector sensors and 4 cam-shaft sensors

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

Adding sheet metal bracket

Now, we have to add sheet metal brackets to provide mounting for the interconnection connector.

Also, we have to make sure that the bracket is placed inside the context assembly and outside of the engine and geometrical bundle assembly. The bracket should be mounted on the existing bolt as shown below. This bracket should have a locking system in a clockwise direction so that it can't be moved freely. In the below figure, the rib is performing the locking feature for the bracket. All the design ideas should be discussed with the engine designing team so that there won't be any disturbance to the smooth working of the engine in real-world applications.

Mounting the interconnection connector on the sheet metal bracket

Here, a 12 pole connector "C-776438-4" and mounting cavity "C-1924487-2" is together used as an interconnection connector. The required CAD data is downloaded from te.com. First, we have to define the 12-pole connector and mounting cavity electrically as below.

Now, we have to mount that electrically connected interconnection connector and cavity on a sheet metal bracket as shown in the above figure.

We have to mount 3 P-clamps also on the existing bolts of the engine so before that we have to define the P-clamp electrically with geometrical parameters, entry and exit points on both the left and right side of the P-clamp as shown in the below figure.

Fur tree clip Defining

First define geometrical parameters such as entry point, entry plane, exit point, exit plane, and base plane. Then switch to the electrical part design workbench and define the fur-tree clip as support using the support command and define the parameters.

Connector 2 pole

Plastic guiding channels

The given V-16 engine has 8 injectors both on the left and right side of the engine which are close to one another, so a plastic guiding channel is used for trouble-free routing of the wiring harness addition it provides thermal protection from high-temperature zones of the engine.

First create geometrical parameters such as bundle entry points, and external reference lines in the part design workbench to route the wiring harness into the guiding channel then define the guiding channel as an electrical part by using the define equipment option to define all the properties to the channel.

Add all the electrically defined components to the geometrical bundle. Place the components at the proper location for routing the harness

Then switch into the electrical harness assembly workbench and the Geometrical bundle product file should be electrically defined using the Define Geometrical bundle option.

Harness routing and packaging

• The available connectors are added to the geometrical bundle and properly positioned onto the fuel injectors, camshaft sensors, vehicle speed sensors, neutral position sensors, and engine coolant sensors. manipulation tool is used to place the connectors.

COT TUBES CREATIONS

Add protective coverings on the wiring harness to protect the wiring from high temperatures. protective covering created by using the define protection part command in the electrical part design workbench. Select a part, and define the parameters as per the requirement.

The created corrugated tube can be added to the catalog by store device command and selecting the catalog file created for protective covering. then appropriate protective covering was added to the bundle segments.

After routing the harness then check the bundle Continuity.

Edit⮕Search⮕Advanced⮕Electrical Workbench⮕Type:-Bundle Segment⮕Attribute:-Fully Connected. Selecting the "TRUE" option in the attribute criterion will show all the connected bundle segment

design criteria followed to route the wiring harness

• Wiring harness routed by considering the factors of ease in manufacturing, accessibility, easy removal, and easy maintenance of attached equipment and routing harness.
• The wiring harness should be routed in such a way that it is easy to assemble on a vehicle.
• The wiring harness should be kept away from sharp environments like sheet metal brackets, panel edges, corners, etc.
• Avoid harness routing and clipping in the blind zone of the operator during harness during installation.
• Ensure that routing meets the clearance requirements with the different surrounding parts.
• Routing shall provide enough slack for each branch to avoid additional stress on the wire and terminal crimping joints but ensure that extra slack does not cause the wiring harness to foul with surrounding parts and impact desired clearance requirements.
• Enough clamps should be provided to ensure positive clearance with the surroundings and the safety of the wiring harness.
• The use of plastic guided channels is recommended to meet the clearances in critical areas if it is difficult to achieve by the use of clamps.
• The branch length should be a minimum of 50mm.
• The minimum distance between the clip and the nearest branching point should be 25mm.
• The minimum distance between two breakouts should be 50mm.
• Limit the no. of branches from a single branch point up to 4.
• Ensure that harness protection is provided according to surrounding temperature, manufacturability, and expected reliability.
• The min. bend radius is to be 1.4.

WIRING HARNESS FLATTENING

Create a new product file for flattening the wiring harness and save as in the same folder where the wiring harness is saved. Then switch to the Electrical harness flattening workbench and select harness flattening parameters and define harness flattening parameters. Before creating the flattened view, Make sure that select 'Double line' for the bundle segment and 'Double' line for protective covering.

We have extracted the bundle assembly into Engine Harness Flattening Product file and then flattened the file along the face of the interconnection connector as shown in the above figure.

At this stage, for clarity, we have hidden the flattening diagram of the plastic guiding channels from the drawing view.

Before creating a flattened view, first, we have to define flattening parameters. Make sure that select 'Single line' for bundle segment and 'Double' line for protective covering.

In the above figure, we are creating a new drawing file and defining all the necessary drawing parameters. We have to insert the front view of the Engine Harness Flattening Product file into the Drawing file.

drafting

PLEASE FIND THE ATTACHED FILE FOR MORE DETAILS