Project 1

AIM

To Route the Wiring harness on Given Engine and Prepare flatten view drawing in CATIA V5

INTRODUCTION

Wiring Harness:

A wiring harness is a pre-assembled set of electrical wires, cables, and connectors that are bundled together in a systematic and organized manner. It is designed to transmit electrical signals and power between different components within a system or device. Wiring harnesses simplify the installation, repair, and maintenance processes by providing a standardized and efficient way to connect electrical components.

Engine Wiring Harness:

An engine wiring harness is a specific type of wiring harness that is designed to provide electrical connections and transmission of signals within the engine compartment of a vehicle. It is responsible for connecting various electrical components of the engine, such as sensors, actuators, ignition coils, fuel injectors, and the engine control unit (ECU).

The engine wiring harness is typically made up of multiple wires and connectors that are specifically tailored to the requirements of the engine and its associated components. It is designed to withstand the high temperatures, vibrations, and environmental conditions found within the engine compartment.

The engine wiring harness plays a critical role in the proper functioning of the engine, as it enables the communication and control of various electrical systems within the engine. Any damage or malfunction in the wiring harness can lead to electrical issues, engine performance problems, and potentially even engine failure.

Flattening:

"Flattening" in the context of a wiring harness refers to the process of removing any twists, kinks, or bends in the wires and cables of the harness to create a flat and organized configuration. This is typically done to ensure proper routing, prevent interference, and optimize space utilization.

During the manufacturing or installation of a wiring harness, the wires and cables are often bundled together and secured with various fasteners, such as tape, zip ties, or clips. Over time, these bundles may become twisted or bent, which can affect the performance and reliability of the electrical connections.

PROCEDURE

• Create an electrical definition for each mechanical connector and save it in the catalogue.
• Put every connector in its proper location on the engine's 3D CAD model.
• P-Clamps and Fir Tree clips should be positioned according to packaging guidelines.
• With all the electrically defined connectors and mounting tools, create the wiring harness routing.
• To generate sub branches and connect to different connections in the geometric bundle, create branching points as necessary.
• As needed, apply protective covers.
• Create a flattening of the wiring harness for the final geometric bundle.
• Create a drawing sheet with the flattened wiring harness using the drafting workbench.

Methodology:

Step 1 :

Download the engine's CAD data from the specified source.

Step 2 :

Download the required Connectors from the source

Mechanical Part into Electrical Part

1. Creation of connector connection point:

• Make a midpoint on the contact face for wire bunddle insertion.
• Create an axis system referencing the newly generated point and specifying the axis direction.
• The Y-Axis should be oriented towards the connector's front face.
• The X-Axis should be oriented towards the clip's locking mechanism.
• The Z-axis should be pointing across the connector from left to right.

2. Creation of Bundle Connection Point.
3. Define the part as a connector and specify terminations.
4. Define Bundle connection point.
5. Define connector connection point.

Inter Connection Connector:

2-pole connector:

4 pole connector:

2-pole connector:

Step 3 :

Download and clamps, clips define as electrical support

• Add two points. both as points of admission and exit.
• Create two planes, plus one at the base.
• Change the part design to electric
• Click on support definition, then part selection, entry point selection, entry plane selection, and base plane selection.
• Again Click on support definition, then select part, select exit point, select exit plane, with the base plane being automatically taken as the secondary plane.

Define Cavity

Assembling interconnection Connector and Cavity

Step 4 :

Download and electrically define the plastic channel

• To create the multi-branch capability utilising an external curve inside the channel, draw a line curve connecting the primary entry and exit locations.
• On the apertures where the injector connectors will be connected, create 8 bundle entrance points.
• Use the define mounting equipment option to define the channel electrical based on the geometrical specifications.
• Use the "define bundle connection point option" to define bundle entry points.

Then New product top and bottom part assemblies should be created.

Step 5 :

Adding connectors to the all 16 fuel injector sensors and 4 cam-shaft sensors.

• Connectors for the cam-shaft and fuel injector sensors are installed in this phase.
• Thus, the Engine Harness Geometrical Bundle Assembly will require a total of 20 connectors.
• In order to place each of the 20 connectors where we want them, we must combine manipulation tools with the compass, snap, and smart move functions.
  

Step 6:

Adding sheet metal bracket

• In order to provide mounting for the interface connector, we must install a sheet metal bracket.
• Additionally, we must ensure that the bracket is positioned outside of the engine and geometrical bundle assemblies and inside the context assembly.
  

• We have to mount the electrically connected interconnection connector and cavity on sheet metal bracket

Connection of 2 pole connectors

Step 7 :

Mounting of electrically define the plastic channel

• We located the guiding channel at the desired location after electrically defining it.
• For installing the guiding channel in this case, we employed a variety of commands, including manipulation, snap, smart move, compass, etc.
• We have just found the bottom of the guiding channel at this point.

Step 8 :

Arrangement of 3 a clamps for bundle routing from interconnection connector

The Assembly is ready for routing

Step 9 :

ELECTRICAL HARNESS

The assembly should have electrically defined connectors and be positioned on the engine surface appropriately.Place the supporting mounting clips in the engine after the connectors are in place to ensure proper routing without entangling the bundle with adjacent components.After completing this route, ensure sure the bundle segment does not collide with the surrounding components.After the geometric bundle is complete, flatten it and check the wiring harness for bundle connectivity.

Step 10 :

Checking the Bundle continuity

• Make sure multi-branchable is first chosen, then proceed to Edit > Search > Advanced > Workbench > Electrical > Type > Bundle Segment > Attribute > Fully Connected.
• The 'True' option will display all linked bundle segments, whereas the 'False' option will display all disconnected bundle segments.
• In this case, we chose the 'True' option and ran a search.
• As illustrated in the below image, all of the bundle segments are highlighted to show that they are all electrically connected.

Step 11 :

Adding protective coverings

For the V16 Engine, we completed the entire wiring harness layout. The top shell of the guiding channel as well as all bundle segments must now be covered with protective materials.

Step 12 :

Flatten view

• We must use Catia V5's Electrical Harness Flattening Workbench to create flat views.
• Additionally, we must ensure that the flattening file is saved in the same directory as the other harness assembly files.
• We must first declare the flattening parameters.
• In order to flatten the file along the face of the interconnection connector, we first extracted the bundle assembly into the Engine Harness Flattening Product file.
• At this point, the flattening diagram of the plastic guiding channels has been removed from the drawing view for the sake of clarity.

X

Step 13 :

Drawing Sheet

• Make a drawing file for the harness product that has been flattened.
• First, we must ensure that bundles and protective covers have distinct graphical representations in the flatten parameter settings
• Single-line illustration of bundle segments
• Coverings used as protection - Double line illustration.

CONCLUSION

In this project, I was able to route the wire harness for the V16 Engine assembly, and CATIA V5 was used to create the flatten-view drawing. While routing the harness, various packaging regulations and restrictions were taken into account. Once the wiring routing is complete, we can ask the relevant Engine design team to install extra holes for mounting Fir tree clips.