Project 1

Wiring Harness For Engine

Aim:

• To route the wiring harness on given Engine and flatten 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.

Objectives:

• The goal of this project is to route a wire harness to a specific engine and create a flattening View in CATIA V5. 
• All kinds of packaging regulations must be considered when wiring wiring harnesses. 
• To design a harness, we need to provide all necessary details such as clearance, clip/clamp selection, harness mounting requirements, harness continuity. 

Engine:

• The Engine has Bugatti 16-valve engine with 8 cylinders on the right side and 8 cylinders on the left side. 
• There are 16 injectors in all, 8 injectors for the 8 cylinders on the right side and 8 injectors for the 8 cylinders on the left side and  also has 4 camshaft sensors, so a total of 20 sensors must be electrically connected.  
• Generally, 4-pole connectors are used for fuel injectors of the engine.
• The engine also has connectors that connect the engine to other parts of the vehicle. Uses a 12-pin electrical connector with mounting clip as connection plug. 

Assumption:

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 1: Create Context Assembly

• As shown in the image above, a contextual assembly for the engine wire harness has been created to serve as the main assembly.
• The context assembly contains engine assembly data for the engine V16 and engine wire harness geometric bundle assemblies.
• If a sheet metal bracket is required, it will be added to the context assembly. 

Step 2:  Define the given connector & clamp has Electrical Part

• First download require connector from the www.te.com for the given Engine
• Then load the connector in the catia v5 and start the defining the connector has electrical part
• Then load the required clamp in the catia v5 and again start the define it has electrical part

Step 3: Adding the connector in the Engine

• Then all connector has added in required placed in the Engine
• And also added Pclamp and fir trip clip added in the required place in the engine

Step 4: Adding the Sheet Metal Bracket

• A sheet metal bracket must be added to attach the connector plug.
• You also need to make sure that the bracket is placed inside the context assembly and outside the motor and geometry bundle assembly.
• The bracket should be attached to the existing screws as shown below. This bracket requires a clockwise locking system to prevent it from moving freely.
• In the image below, the ribs perform the latching function of the bracket. Design ideas should be discussed with the engine design team so as not to affect the smooth operation of the engine in real applications. 

Step 5: Mounting the Interconnection connector on Sheet Metal Bracket

• Here, the 12-pin connector "C-776438-4" and mounting hole "C-1924487-2" are used in combination as the mating plug.
• Download the required CAD data from te.com. First, we need to electrically define the 12-pin connector and the mounting cavity as follows
• A 12 pole connector "C-776438-4" is electrically defined as Mention Below
• A mounting cavity "C-1924487-2" is electrically defined as Mention below

 

• The image above shows both the 12-pin connector and the mounting cavity in the electrical assembly design workbench are electrically connected.
• Now we need to attach this electrically connected connector plug and cavity to the sheet metal support as shown in the image above. 

Step 6: Mounting guiding channel

• The V16 engine has 8 injectors on the right side and 8 on the left side, which are so close together that a plastic guide channel has to be added.
• Plastic guide channels are therefore the best option for proper and easy routing of wire harnesses.
  
• Reduces complex wire harness routing. Two different guide channels are required for the right and left sides of the engine. 
• Now, before placing guiding channel, we have to define geometrical parameters and also electrical define for the guiding channel as mention  below.

• After defining the guide channel electrically, we placed the guide channel in the desired location as shown in the image above.
• Here I used various commands such as Manipulate, Snap, Smart Move and Compass to position the guide channel. 

Step 7: Bundle routing for all the connector

• Let start the Bundle routing process were interconnection to the 3 fir trip clip so select the bundle routing option and select the routing place 
• Then given diameter has 10mm For the main brance and also select the bend radius has 1.2

• Now wiring the cam shaft sensor by using bundle routing and the given diameter has 10mm and also the bend radius has 1.2

• Then Wiring the given 2 pole connector with the help of bundle routing and given diameter has 5mm and bend raidus has 1.2
• Then routing to the plastic guiding channel for our required length and also given diameter has 10mm and bend radius has 1.2 and image were mention below
• Then connect the connector throught the guiding channnel with the help of bundle routing and given diameter has 5mm and bend radius has 1.2

Step 8: Adding protective covering and top guiding channel

• In the image below the entire wiring harness routing for the Bugatti V16 engine is complete. Now you need to attach protective covers to all bundle segments and duct top shells. 

Step 9: Check Bundle continuity

• First you need to make sure Multi-branchable is selected. Then you need to go to Edit > Search> Advanced > Workbench-Electrical > Type-Bundle Segment > Attribute-Fully Connected. 
• Select the True option to display all connected bundle segments, or select the False option to display all unconnected bundle segments.
• Here we have selected the True option and checked the results. All bundle segments are highlighted to indicate that they are electrically connected, as shown in the following figure. 

Conclusion:

         This is how you wire the wiring harness for your Bugatti V16 engine. I also created the plan using the correct sheet in CATIA V5. 

FILES:

• Files were uploaded in the name of "Project 1.zip"