Project 1

WIRING HARNESS FOR ENGINE

AIM:

• To route the wiring harness for the given engine.
• Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design.
• Apply Protection coverings as required.

INTRODUCTION:

WIRING HARNESS OR CABLE HARNESS:

A cable harness, also known as a wire harness, wiring harness, cable assembly, wiring assembly, or wiring loom, is an assembly of electrical cables or wires which transmit signals or electrical power. The cables are bound together by a durable material such as rubber, vinyl, electrical tape, conduit, a weave of extruded string, or a combination thereof.

Cable harnesses are usually designed according to geometric and electrical requirements. A diagram is then provided (either on paper or on a monitor) for the assembly preparation and assembly.

The wires are first cut to the desired length, usually using a special wire-cutting machine. The wires may also be printed on by a special machine during the cutting process or on a separate machine. After this, the ends of the wires are stripped to expose the metal (or core) of the wires, which are fitted with any required terminals or connector housings. The cables are assembled and clamped together on a special workbench, or onto a pinboard (assembly board), according to design specification, to form the cable harness. After fitting any protective sleeves, conduit, or extruded yarn, the harness is either fitted directly in the vehicle or shipped.

COMPONENTS:

(a).Connectors:

1. Part No : C-173090-2

No of terminals: 2

No of Quantity : 1

USE : Ignition

2. Part No : C-282080-1

No of terminals : 2

No of Quantity : 2

3. Part No : C-1563689-1

No of terminals: 4

No of Quantity : 20

4.Part No : C-776438-4

No of terminals: 12

No of Quantity : 1

USE: Ingnition power supply

(b).Mounting Equipment:

1. Part No : C-1924487-2

No of Quantity : 1

2. P Clamp:

3. Furr tree clip:

4. Channel

Bottom channel:

Top channel:

GIVEN ENGINE:

PACKAGING RULES:

• Wiring harness routing shall provide ease in manufacturing, accessibility, easy removal, and easy maintenance of attached equipment and wiring harness.
• Routing through small structural holes and openings shall be avoided, minimize 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 handhold 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 to the bolted joints. It may damage the harness or puncture the harness. Keep harness 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 clip and branching point to be 25 mm.
• Min distance between two branch breakouts should be 50 mm.

HARNESS ROUTING:

ROUTING BUNDLE:

HARNESS CONNECTIVITY CHECK:

In this step, first we have to make sure that multi-branch able 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 False option and searched for results. No bundle segments are highlighted found showing that means all the bundle segments are electrically connected.

Checking for continuty

Checking for discontinuty

Harness Flattening Procedure:

• Harness flattening can be created from the Electrical Harness Flattening Workbench in CATIA V5.
• Create a new product file in the Electrical Harness Flattening workbench and rename it as of our requirement.
• Select the product file and define Flattening parameters to it. And we can rename it as of our requirement.
• Save the flattening product file in the save folder which is having all the other required documents.
• Create vertical windows with Harness assembly product and flattening product files.
• Using the Extract option, extract the harness assembly into the flattening product.
• Convert the extracted harness assembly into the flattened harness assembly by using the Flatten command.

CREATE A FLATTEN VIEW DRAWING:

Now we're creating a new drawing file and defining all of the required drawing parameters. The front view of the Backdoor wire Harness Flattening Product file must be inserted into the Drawing file. It should be noted that the 3D wireframe is always ON in the 'Dress up settings. If this option is not enabled, the bundle segments will not be visible in the drawing view. the Backdoor wire Harness Flattens view's final Drawing view.

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.

CONCLUSION

3D representation and 2D drawing of the engine harness are implemented, Engine harness is taken as a case study and developed the geometrical bundle assembly without fouling the bundle segments.