Project 1

Project-1

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. And also applying Protection coverings as required.

The above figure shows that the engine has 16 valve injectors where the 8 cylinders are placed on the right side and 8 cylinders are placed on the left side.

Also there are 4 cam-shaft sensors, so there are total 20 sensors that we have to connected electrically.

Here I'm using the 4 pole connector because 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.

Initially we want to create the context assembly which has the all geometric and wiring harness product in it.

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 Engine and Engine Harness Geometrical Bundle Assembly.
• If any sheet metal bracket will require then they are added in the context assembly.

Then we decided to place the connectors to the injectors in this assembly. Before connecting the connectors to its required place first we should define the geometrical parameters like bundle connection point and connector connection point in Electrical Part Design workbench for the downloaded connector.

PACKAGING RULES:

• Wiring harness routing shall provide ease in manufacturing, accessibility, easy removal, and easy maintenance of attached equipment and wiring harnesses.
• Routing through small structural holes and openings shall be avoided, minimizing chaffing and handling of the wiring harness during installation.
• Avoid the harness routing and clipping in the Blind zone of the Operator during harness assembly or in service.
• Routing shall offer protection against possible damage through common misuses such as being handheld and temporary support for test equipment.
• Provide additional slack to the harness according to the surroundings and harness bending requirements.
• Ensure the routing meets the clearance requirements with different surrounding parts.
• Avoid routing over the bolts, near the bolted joints. It may damage the harness or puncture the harness. Keep harnesses away from panel mounting screws.
• Avoid harness routing near sharp edges, if not possible provide protection to the harness.
• The maximum distance between two clips on a straight branch is 200mm.
• Provide Clips and clamps if the harness is going to bend at multiple locations.
• The use of too many sheet-metal brackets should be avoided.
• The branch length should be more than 50 mm.
• Min distance between the clip and the branching point is to be 25 mm.
• Min distance between two branch breakouts should be 50 mm.

Assumptions-

1. Provide clips/clamps as per requirement.
2. Make sure that there is no falling case while designing the wire harness. Additional clips/clamps may be used to avoid falling cases.
3. Give additional slack if needed. 5-10% slack is sufficient.
4. Avoid routing over the 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 the surrounding temperature.
8. Avoid direct support for harnesses on fuel lines routed in the engine.
9. Use plastic guiding channels if needed.
10. The branch length should be greater than 50mm.
11. The minimum distance between two branch points should be at least 50mm.
12. The minimum distance between the clip and the 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 is practical. Bundle diameters and other 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 a harness channel that can be used to route and protect the wire harness effectively.

Step-2: To define the connector electrically for injector

Here, according to the requirement we are using 'C-1563689' which is a 4-pole connector. This CAD data is downloaded from te.com.

Step-3: Adding the connectors to the 16 injectors and the 4 cam shaft sensors

In this step, we are placing connectors to fuel injector sensors and cam-shaft 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 and smart move features to locate all the 20 connectors at their desired locations.

After I decided to add the connector to the coolant temperature sensor and Vehicle speed measurement sensor in the wiring harness assembly.

Before connecting the connector, first we should define the connector electrically like bundle connection point and the connetor connection point.

The above figure shows that 2 pole connector (C-282080-2) is used for connected with the Coolant temperature sensor on the middle of the engine. And also the Vehicle motion sensor is fixed with this connector.

After I decided to connect the connector to the Neutral Position Transmission Sensor.

Before connecting the connector, first we should define the connector electrically like bundle connection point and the connetor connection point.

The above figure shows that 2 pole connector (C-173090-2) is used for connected with the Neutral Position Transmission sensor on the middle of the engine.

Step 4: Adding sheet metal bracket

Now, we have to add sheet metal bracket in order 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 engine and geometrical bundle assembly. The bracket should be mounted on the existing bolt as shown below. This bracket should have locking system in clockwise direction so that it can't be move freely. Herein below figure, 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 for the smooth working of engine in real world application.

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

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

• A 12 pole connector "C-776438-4" is electrically defined as shown in above figure.

• A mounting cavity "C-1924487-2" is electrically defined as shown in above figure.

• Above figure shows that, both 12 pole connector and mounting cavity are electrically connected together in electrical assembly design workbench.

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

• We have to mount 3 fir tree clamps also on the existing holes of the engine so before that we have to define fir tree clip electrically with geometrical parameters, entry and exit point on both left and right side of the Fir tree clip as shown in below figure.

• Here, we have mounted 3 Fir Tree clips on the existing holes of the engine for the wire harness routing as shown in above figure.

• In above figure, we have mounted furr tree clip also for the smooth path to wiring harness routing towards guiding channel on both right and left side.

Step 6: Mounting of a plastic guiding channel

We have to add now plastic guiding channel because the engine has 8 injectors on right side and 8 injectors on left side which are very close to each other. Hence plastic guiding channel is best option for proper and easy routing of the wiring harness. It will reduce the complex wiring harness routing. We will require two different guiding channel for both right and left side of the engine. Now, before placing guiding channel, we have to define geometrical parameters of guiding channel as below.

• In above figure, we have created point 1 at entry face and another point at endpoint at 560mm distance.
• Now, join that both points and create a line which will be later used for routing the wire harness bundle inside the guiding channel.
• The above figure shows the left side guiding channel and we want the right side guiding channel.
• So, I decided to copy this channel and mirrored it by using the steps for mirroring Insert -->Transformation Features --> Symmetry and then I choose the plan for mirroring. Then it will mirrored for the right side guiding channel. It is shown below.

Then I decided to create the bundle connection points for these 2 of the channels and then I've created the Assembly guiding channel product for this Engine assembly then added with the Geometric Bundle for wiring harness routing.

• After electrically define of guiding channel, we have located guiding channel at desired place as shown in above figure.
• Here, we have used different commands like manipulation, snap, smart move, compass etc. for placing of guiding channel.

Then the whole assembly of the engine is ready for the routing. All 20 connectors, 3 Fir Tree clips, 1 Interconnection connector and 2 plastic guiding channels are mounted.

Step 7: Bundle routing from Interconnection connector to 3 Fir tree clips

Here, we are routing the bundle segment from interconnection connector to 3 Fir Tree clips. The diameter for this routing path is 5mm and bend radius ratio is assumed to be 1.5.

Step 8: Adding branch points to 4 cam-shaft sensors

Adding branch point to the bundle segment at distance of 40mm from Fir tree clip as shown in below figure.

Then I decided to make the branch point at the middle by using the bundle segment definition in the window then I fix the distance between the Interconnection connector to fir tree will be 50mm. Then I routed the camshaft sensors with the wiring harness.

The above figure shows that Cam shaft sensor wire routing was completed.

Step 9: Routing to the plastic guiding channel

Another branch point is added from the interconnection connector at distance of 50mm. From this branch point, the bundle is routed to the right guiding channel. We have provided furr tree clip in between branch point and guiding channel for the smooth routing.

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

Above figure shows that we are adding the branch points to it and then we are going to route the wiring in this guiding channel on both sides.

The above figures shows that routing was done for the 16 injectors for left and right side of the engine.

Then I decided to route the wiring harness for the Engine Coolant Temperature Sensor, Vehicle Speed Measurement Sensor and Neutral Position Transmission Sensor.

In the above figure I routed the wiring on the 3 sensors by using the branch definition.

Step 11: Adding protective coverings to harness bundle

In the below figure, we have done with whole wiring harness routing for the Engine. Now, we have to add protective coverings to all bundle segments and top shell of the guiding channel.

Here I'm using the bundle segment diameter for all is going to be 5mm because I'm using the fir tree clip for this routing on the engine. I'm having error with P-Clamps, so I decied to do with fir tree clip. It has only the 5mm on its path.

In the above figure I've added the protection covering of Slit COT tubes of 10mm for all of the bundle segments.

• In above figure, we have added all the slit COT tubes on bundle segments as a protective coverings. Also, we have added top of the both left and right side plastic guiding channel.

Step 12: Checking bundle continuity

In this step, first we have to make sure that multi-branchable is selected then we have to go in 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 as shown in below figure.

Here, we have selected for the 'FALSE' option and searched for results.

There is no discontinuity in this wiring harness routing by getting no bundle segment in this window search results.

Step 13: Creating flatten view of the engine harness geometrical bundle assembly

In this step, for creating flatten view we have to work in Electrical Harness Flattening workbench of Catia V5. We should also make sure that the flattening file is saved in the same folder where other files of harness assembly are saved.

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

I tried more than 3 times for to complete this project but I'm having this electrical software error in the flatten command.

So, I decided to draft the drawing in the actual diagram in the geometrical assembly.

Step 14: Creating a flatten view drawing for the wiring harness assembly

• Now, we have to make new drawing file and define all the necessary drawing parameters as shown in below image.

• It should be noted that for the Dress-up feature 3D wireframe is always ON. If this setting is not selected then the bundle segments will not be visible on the drawing view.

Final draft of the model :