Project 1

Aim:  Route wiring harness for given engine. Apply all the packaging rules to the same and add protection covering where required.

Introduction

            The main objective of this project is to route the wiring harness of a V16 engine using the appropriate design criteria having the required clearance, using the right clips/clamps and mounting equipment’s.

Packaging rules followed in the project:

1. Additional slack is provided wherever required to avoid fouling with the engine.
2. Additional clamps/Clips are used to avoid fouling wherever necessary.
3. Avoiding routing over bolted and screwed joints to avoid harness puncture.
4. Minimum use of mounting brackets.
5. Branch length is minimum 50mm.
6. Wiring harness is easy to assembly and practical.
7. Avoid routing in hard-to-reach places by technician.
8. Avoid support on fuel lines.
9. Routing away from exhaust regions.
10. Protection provided wherever necessary.

The given engine has 16 mountings for injectors connectors in addition to the 4 cam shaft connectors, for which 4 pole connectors ae required. For other sensors mounted on the engine 2 pole connector is used. For interconnection connector a 12-pole connector is used. Interconnection connector will connect the engine with other part of vehicle.

P-clamp for 20mm diameter is used along with furr tree clip.

Assembly of Engine Wiring Harness:

Step 1:

Defining all the connectors and supports required as electrical components.

   

Connectors: 4-Pole connector, 2-Pole connector and interconnection connector.

Supports: P-Clamp, to smoothly route the harness so that it does not hang loosely over the engine.

 

Furr Tree Clip, to guide the harness safely without fouling with the engine.

Mounting Cavity Clip for innterconnctor.

 

Guiding channel: To route the harness for the injectors with better protection as it is closer to the exhaust as well as for clean and organized routing. It needs to be of a material that needs to withstand high temperatures.

Step 2:

Creating a product of the engine and all the connectors and support equipment for routing. Positioning all the connetors at the approx places for routing.

Connector mountings (in red) and Guiding channel positioning.

 

Mounting for interconnector: The interconnector is mounted over a sheet metal such that it away from all the other harnessing. Existing bolts and screws are used so that no other operation is needed for mounting of the wiring harness which is easier for manufacturing and assembling.

  

P-clamps (Highlighted) are mounted on the already existing bolts for easy fuss free assembling. 

 

Furr tree clip mounting (highlighted) and cam shaft (in red) connector postioning 

Sensor Connectors (highlighted)

Additional mounting holes need to be created for accommodating furr tree clip and guiding channel.

Step 3:

Routing the harness and checking for the continuity of the same to ensure all the multibranchables are fully connected.

 

Adding slack to the harness to avoid fouling with engine.

Routing through guiding channel.

Geometrical Bundle of wiring harness.

Bundle Continuity is fully connected as there are no branches displaced for "FALSE" search.

Step 4:

Adding protection covering for safety from chaffing and damage wherever it is required.

 

Step 5:

Creating a fattening product of the multibrancable before drafting.

 

Step 6:

Creating a draft for further manufacturing and assembling departments after converting to .pdf format.

 

Conclusion:

Routing of the engine was done and flattening of the same for done for drafting. All the industry best practices were considered while routing the harness. All necessary clearances, harness fixing requirements, harness continuity was provided while designing the wiring harness.