Project 1

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 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.

Connector Definition

• Download 3D Connector

Mechanical Part Design Workbench -

• Defining Geometrical Parameters (Points and Axis system)

1. Bundle entry side center point

Selecting required random points to get a center point for a suitable point type.

2. Mating side center point

Selecting required random points to get a center point for a suitable point type.

3. Mating side axis system

Creating an axis system concerning the center point as the origin of the axis. The Y axis is directed at the mating direction, the X axis is directed towards the locking side and the Z axis is directed upwards.

Electrical Part Design Workbench -

• Define part as Connector

Defining part as an electrical connector in Electrical Part Design Workbench using 'Define Connector', and also selecting the number of terminations for the connector.

• Define Bundle Connection Point

• Define Connector Connection Point

• Define cavity connection point (if connector needs mounting clip)

A cavity connection is defined as the connecting part for a connector clip where representation is the center point of the cavity connection, contact is the connection face, coincidence is the Y axis and, orientation is the X axis.

A catalog is also been created for all the electrical components and can be used for the Geometrical bundle assembly, through 'Catalog Browser'.

Preparation of the Harness Assembly

1. Harness Context Assembly

All the supportive context and Geometrical Bundle Assembly are the components of the harness context assembly.

2. Geometrical Bundle

Mechanical Assembly Design

• Catalog Browser

All the electrical connectors are loaded in the geometrical bundle using Catalog Browser from their catalog. Manipulation, Snap, and Compass are the tools used from the mechanical assembly design workbench to place the connectors at the desired positions of the sketch.

Electrical Harness Assembly

• Geometric Bundle

The geometric Bundle command is used to electrify the geometrical bundle.

• Multi-Branchable Document

The multi-Branchable Document command is used to initiate branches for the electrical components using Branch Definition.

Electrical Harness Installation

• Branch Definition

The Branch Definition command is used to define the branches between the components. Branch diameter, Bend Radius (ratio 1.4), and Build Mode (slack) are set in the branch definition before proceeding with the Route Definition.

In Route Definition, objects/components are selected for which the branches are to be made.

• Add Branch Point

Branch points are created from the main branch using Add Branch Point command. The branch is selected for which the branch point is to be created and distance is defined as per the packaging guidelines for the branch point. New branches can be created through the same branch point.

• Protective Covering

Protective covering (COT Tubes) on all branches are connected with the end extremity of 30/20mm (from the end of the connector). Bundle segments are selected then the protective coverings are implemented using the COT Tubes catalog.

Conclusion:

In this way, we have routed wiring harness for the Bugatti V16 Engine. Also, prepared flatten view drawing with proper sheet in CATIA V5.