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 hamess 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 hamess 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.

The given engine model has 16 fuel injector sensors and 4 cam-shaft sensors that is a total opf 20 sensors.We used 4 pole connectors for fuel injector sensors and for cam-shaft sensors also.

The engine will also have an interconnection connector which will connect the engine to other parts of the vehicle.We used 12-pole electrical connector with a mounting clip feature as an interconnection connector.

The plastic guiding channel used in this harness should be made of a material that can withstand atleast 150 deg celcius.

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.

Creating Context Assembly:-

Defining the connectors ,electrically:-

The 4-pole connector used for this harness assembly is "C-156389-1". The 3D CAD data for this connector was downloaded from TE.com. To define the connector electrically we should define the geometrical parameters, bundle connection point, and the connector-connection point for the downloaded connector.Similarly we can use C-776438 connector to define those connectors are electicaly

Plastic Guiding Channel

The V16 engine has 8 fuel injectors on the left side and 8 fuel injectors on the right side of the engine. All these fuel injector sensors are located very close to each other. So, the best way to route the wires around them is by using a plastic guiding channel as they will help us organize all the wires very precisely and will reduce complex wiring harness routing. To mount the plastic guiding channels we would need some mounting provisions. The engine design team can be consulted and asked to provide mounting threaded holes or threaded bosses.

There will be two different plastic guiding channels for this engine. One for the left and theother for the right side of the engine. It has to bemade sure that proper clearance (at least 50mm) is provided between the plastic channel andthe exhaust pipes. The total thickness of thethese channels is 25 mm.

The plastic guiding channel will be a two-piece molded plastic that will protect the wiring harness from surrounding high temperatures, wear and tear while providing nice aesthetics to the engine

Locating the Guiding channel:-

Use manipulation, compass, snap and smart move commands to locate and move the guiding channels in place as shown below. These channels are added inside the engine harness geometrical bundle. At this stage, we will only add the bottom part of the left and right guiding channels

Engine with all mounting and guiding provisions:-

The image below shows all 16 connectors ,2 plastic guiding channel ,2 p-clamps,2 furr_clips and interconnection connector mounted on the sheet -metal bracket

Routing to the guiding channel:-

Another branch point is added at 55mm from the interconnection connector. From this branch point, the bundle is routed to the right side guiding channel. It can be noticed that there is no need of any additional mounting provisions for this bundle segment as the bundle path is practical and completely possible in the real world situation.

Checking Bubdle Continuity:-

First, we have to make sure that multi branchable is selected and then we have to go in WORKBENCH>TYPE-BUNDLE

EDIT>SEARCH>ADVANCED>ELECTRICAL

SEGMENT>ATTRIBUTE-FULLY CONNECTED

Selecting the "TRUE" option will show all the connected bundle segments while the selecting "FALSE" will show all the non-connected bundle segments.

For now, we will select "TRUE" and search for results. All the bundle segments are highlighted and found showing that all the bundle segments are electrically connected