Project 1

Route the following harness layout in Electrical workbench

OBJECTIVE:- Route the Wiring harness on Given Engine and Prepare flatten view drawing in CATIA V5.

Download connector 3D data from www.te.com

INTRODUCTION

A wire harness, also commonly referred to as a wiring harness, is an exterior sheath used to cover some types of electronic wires. Generally, wiring harnesses are made of thermoplastic or thermoset materials that can help protect the cables from the environment.

Engine Harness

An engine wiring harness is constricted wires, cables, terminals, and connectors controlling a vehicle’s electrical system. It relays electrical power and control information to components such as batteries, alternators, fuel injectors, fuses, audio systems, blower motors, fuel injectors, and computers. Wire harness companies customize it for every location, application, and design it interconnects. Also known as a cable harness, it is more than just a collection of multiple wires put together.

It manages the key functions around the engine including engine controller, oil controller gate, transmission plug housing, air pipe sensors, pressure sensors, and water temperature sensors.

An engine wiring harness is how each part of your vehicle gets electricity. It is crucial to help the vehicle run and it’s usually made of a heat-resistant rubber to handle the high and low temperatures that vehicles often experience. The vehicle needs more than the engine, and it requires a lot of electricity for certain things to function, like the radio or lights. Beyond that, battery, starter, and even alternator run on power, which is provided by the engine. Without an engine wiring harness, we couldn’t start your vehicle.

How Does the Engine Wiring Harness Work?

There are many cables in the engine wiring harness that work to connect electricity to your vehicle parts. This vehicle part has many sensors, and they work to ensure that everything in your vehicle is in working order. Some of these major systems in your car are fuel and transmission. When you get a check engine light, you have the engine wiring harness to thank.

It works by using these cables and a fuse box. They wire the electricity produced by the engine to the various parts and sensors. It is created using high-temperature plastic or rubber because the engine heats up a lot. That could cause the engine wiring harness to melt over time. And while this is a rare occurrence, it does happen.

Think of this part of the vehicle like the brain. Without it, it wouldn’t be possible to get the information your vehicle needs. It’s always working overtime to relay the data your vehicle needs to function correctly. Whenever a sensor goes off, it’s because the engine wiring harness alerted the sensor of the problem

The exciting thing is that as vehicles get more advanced, the engine wiring harness grows. Some say that new cars have over 100 pounds of wires, so imagine how many things could go wrong with that. In the past, there may not have been many issues. However, as things advance, there are more to go wrong.

Engine Wiring Harness protection

Protecting the wires is crucial to the safety of the vehicle. Wires exposed to high temperatures, erosive chemicals and projectiles will be damaged leading to fires, brake failures and critical malfunctions. To prevent these issues, wires need to be bundled and covered.

install wiring insulation or heat shield sleeve material that can withstand direct contact with high-temperature surfaces and is flameproof. It needs to be a material built specifically for under hood automotive applications and withstand constant temperatures up to 125°C, or 257°F.

There are many options for protecting the wires in a vehicle’s harness. Zip ties securely bundle wire together but offer little protection or insulation. Plastic conduits offer protection from rough surfaces, although they can add weight and are not as flexible as other options. Heat-shrink tubing provides protection from heat, moisture and chemicals. However, the application is time-consuming.

Tape is another option for bundling and protecting wires. Tapes are more flexible and cost-effective than other bundling options because they can be used for protective wrapping, bundling and sealing. With a wide variety of backings and adhesives, tape can offer sound dampening, thermal and electrical insulation and abrasion protection of the same quality of the other methods. Additionally, tapes are more flexible, lighter and easier to apply than tubing or plastic conduit.

DESIGN & ROUTING METHODOLOGY

• Download the Connectors 3D data from te.com
• Open the downloaded Connectors in Part Design workbench of Catia and Save as .CATPart
• Open each Connector and Create
  • Connector Connection Point
  • Bundle Entry Point
  • Axis system on Connector Connection Point and Align the Y-Axis in Mating direction & X-Axis in the direction of Lock.
• Open each connector in Electrical Part Design workbench & Define Electrical properties.
  • Click on Define Connector Symbol and then select the part.
  • Click on Define Bundle Connection Point Symbol and fill the opened dialogue box.
  • Click on Define Connector Connection Point Symbol and fill the opened dialogue box.
  • Save the Part as Electrical Part.
• Create one Product file in Assembly design workbench as Assembly_Context_Engine_Harness
• Create another Product file in Assembly design workbench as Geometric Bundle under Assembly_Context_Engine_Harness
• Add all connectors under the Geometric Bundle in Assembly design workbench.
• Place all the connectors at desired locations as per given picture using Manipulation, Snap & Smart Move option.
• Now open the Geometric Bundle Assembly in Electrical Harness Assembly workbench.
• Click on Geometrical Bundle Symbol and select Geometric Bundle Assembly to defile Geometric Bundle Assembly as Electrical.
• Now Click on Multi-branchable Symbol and fill the opened dialogue box.
  • Bundle Diameter
  • Bundle Bend Radius ( Ratio must be > 1.4 )
  • Build Mode As slack
• Now Click on Route definition
  • Select C-776438-4.1 Connector & P clamp.
• Now repeat last steps to complete the given harness routing.
• Now create Electrical harness Flattening file & define Harness Flattening Parameters
• Now click on Extract and select the File to be flatten i.e. Geometric Bundle
• Now click on Flatten to Flat the assembly.
• Now Create Drafting file to create the drawing of flatten Assembly.
• Select the Sheet Size As A0 & Place the view by clicking on Front View option.
• Now save the drawing file.

Harness Assembly Steps

Step-1 Download the Connectors 3D data from www.te.com

Step-2 Open the downloaded Connectors in Part Design workbench of Catia and Save as .CATPart

Step-3 Create one point on mating surface of Connector & rename it to Connector Connection Point.

Step-4 Create one point on Bundle Entry surface of Connector & rename it to Bundle Entry Point.

Step-5 Create Axis system on Connector Connection Point and Align the Y-Axis in Mating direction & X-Axis in the direction of Lock.

Step-6 Now open the Electrical Part Design workbench of Catia & Click on Define Connector Symbol and then select the part.

Step-7 Now click on Define Bundle Connection Point Symbol and fill the opened dialogue box.

In Representation – Select the Green Highlighted Surface

In Point – Select the Bundle Entry Point

In Initial Conditions – Select the Green Highlighted Surface

Step-8 Now click on Define Connector Connection Point Symbol and fill the opened dialogue box.

In Representation – Select the Connector Connection Point

In Contact – Select the Green Highlighted Surface

In Coincidence – Select the Y-Axis

In Orientation – Select the X-Axis

Step-9 Save the Part as Electrical Part.

Step-10 Repeat same Steps for all Connectors & save them as Electrical Part.

Step-11 Create one Product file in Assembly design workbench as Assembly_Context_Engine_Harness

Step-12 Create another Product file in Assembly design workbench as Geometric Bundle under Assembly_Context_Engine_Harness

Step-13 Add all connectors under the Geometric Bundle in Assembly design workbench.

Step-14 Place all the connectors at desired locations as per given picture using Manipulation, Snap & Smart Move option.

Step-15 Now open the Geometric Bundle Assembly in Electrical Harness Assembly workbench.

Step-16 Click on Geometrical Bundle Symbol and select Geometric Bundle Assembly to defile Geometric Bundle Assembly as Electrical.

Step-17 Now Click on Multi-branchable Symbol and fill the opened dialogue box.

• Bundle Diameter
• Bundle Bend Radius ( Ratio must be > 1.4 )
• Build Mode As slack

Step-18 Now Click on Route definition

• Select C-776438-4.1 Connector & P clamp.

Step-19 Now repeat last two steps to complete the given harness routing.

Step-20 Now create Electrical harness Flattening file & define Harness Flattening Parameters

Step-21 Now click on Extract and select the File to be flatten i.e. Geometric Bundle

Step-22 Now click on Flatten to Flat the assembly.

Select the desire plan i.e., Face of Connector

Then select the Geometric_Bundle_Ehf and click ok to flatten the assembly.

Step-23 Now Create Drafting file to create the drawing of flatten Assembly.

Step-24 Select the Sheet Size As A0 & Place the view by clicking on Front View option.

Step-25 Now save the drawing file.