Project 1

Aim- To route the wiring harness on given Engine and flatten view drawing in CATIA V5.

Objective- The objective of the project is to route the wiring harness on given V16 Engine and prepare flatten view drawing in CATIA V5. All types of packaging rules have to be considered while routing the harness. Also, Industry best practices should be demonstrated in design. All the necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design wiring harness.

Theory :

The given V-16 engine consist of following electrical components to which harness routing is required.

• 8+8 fuel injectors on the engine cylinders for both sides of the engine block (16 injectors), which are connected by a 4 pole connector with the wiring harness.
• 2 camshaft sensors on each engine block (4 camshaft sensors), which are connected by a 4 pole connector with the wiring harness.
• Engine coolant sensor at the centre of the engine between the two blocks, which is connected by a 2 pole connector, with the wiring harness.
• Engine oil temperature and pressure sensor fitted at the oil sump of the engine on both engine cylinder blocks, which are connected by a 2 pole connector with the wiring harness.
• 1 sensor to measure vehicle speed, which is connected by a 2 pole connector, with the wiring harness.
• 1 sensor to sense neutral positon of the transmission assembly, which is connected by a 2 pole connector, with the wiring harness.
• An interconnection connector to connect engine harness system to vehicle harness system.

Other equipments required to complete the wiring harness routing

• Guiding channels to protect the harness routing from high heat zones of the engine wherever necessary.
• P-clamps to provide positive clamping and ensure clearance management for the routing wherever necessary.
• Sheetmetal brackets such as L-clips to mount the interconnection connector.
• Mounting clips to mount the connectors whenever required.
• Corrugated protection tubes to protect the wiring harness.

Assumptions-

1. Provide clips/clamps as per requirement.
2. Make sure that there is no any fauling case while designing the wire harness. Additional clips/clamps may be used to avoid fauling case.
3. Give additional slack if needed. 5-10% slack is sufficient.
4. Avoid routing over 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 surrounding temperature.
8. Avoid direct support for harness on fuel lines routed in the engine.
9. Use plastic guiding channels if needed.
10. Branch length should be greater than 50mm.
11. Minimum distance between two branch points should be at least 50mm.
12. Minimum distance between clip and 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 that are practical. Bundle diameters and another 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 harness channel which can be used to route and protect the wire harness effectively.

Step 1: Creating Context Assembly

• A Context Assembly for Engine Harness has created which will work as the main assembly as shown in above figure.
• A Context Assembly will contain Engine Assembly data for Bugatti V16 Engine and Engine Harness Geometrical Bundle Assembly.
• If any sheet metal bracket will require then they are added in the context assembly.

Step 2: To define 4-pole connector electrically

Here, according to the requirement we are using 'C-1563689' which is a 4-pole connector. This CAD data is downloaded from te.com. Now, to define a connector electrically we should define the geometrical parameters like bundle connection point and connector connection point in Electrical Part Design workbench for the downloaded connector.

Step 3: Adding connectors to the all 16 fuel injector sensors and 4 cam-shaft sensors

In this step, we are placing connectors to fuel injector sensors and cam-shaft sensors. So we will require total 20 connectors which have to be added in the Engine Harness Geometrical Bundle Assembly. We have to use manipulation tools along with compass, snap and smart move features to locate all the 20 connectors at their desired locations.

Step 4: Adding sheet metal bracket

Now, we have to add sheet metal bracket in order to provide mounting for the interconnection connector. Also, we have to make sure that the bracket is placed inside the context assembly and outside of engine and geometrical bundle assembly. The bracket should be mounted on the existing bolt as shown below. This bracket should have locking system in clockwise direction so that it can't be move freely. Herein below figure, rib is performing the locking feature for the bracket. All the design ideas should be discussed with the engine designing team so that there won't be any disturbance for the smooth working of engine in real world application.

Step 5: Mounting the interconnection connector on the sheet metal bracket and mounting the p-clamps for wire harness

Here, a 12 pole connector and mounting cavity is together used as interconnection connector. The required cad data is downloaded from te.com. First, we have to define 12 pole connector and mounting cavity electrically as below.

• Now, we have to mount that electrically connected interconnection connector and cavity on sheet metal bracket as shown in above figure.
• We have to mount 3 P-clamps also on the existing bolts of the engine so before that we have to define P-clamp electrically with geometrical parameters, entry and exit point on both left and right side of the P-clamp as shown in below figure.

• Here, we have mounted 3 P-clamps on the existing bolts of the engine for the wire harness routing as shown in above figure.

Step 6: Mounting of a plastic guiding channel

We have to add now plastic guiding channel because V16 engine has 8 injectors on right side and 8 injectors on left side which are very close to each other. Hence plastic guiding channel is best option for proper and easy routing of the wiring harness. It will reduce the complex wiring harness routing. We will require two different guiding channel for both right and left side of the engine. Now, before placing guiding channel, we have to define geometrical parameters of guiding channel as below.

• In above figure, we have created point 1 at entry face and another point at endpoint at 560mm distance.
• Now, join that both points and create a line which will be later used for routing the wire harness bundle inside the guiding channel.
• Above figure shows for the left side guiding channel and same process will be repeated for the right side channel.

• Now in above figure, we have created bundle entry points for the eight connectors, one bundle entry point at channel entry face and defined guiding channel electrically as equipment.

• In above figure, we have shown bundle entry point at face of guiding channel.

• After electrically define of guiding channel, we have located guiding channel at desired place as shown in above figure.
• Here, we have used different commands like manipulation, snap, smart move, compass etc. for placing of guiding channel.
• Now at this stage, we have just located bottom of the guiding channel.

• In above figure, whole assembly is ready for the routing.
• All 20 connectors, 3 P-clamps, 1 Interconnection connector and 2 plastic guiding channels are mounted.

Step 7: Bundle routing from All 20 connectors, 3 P-clamps, 1 Interconnection connector and 2 plastic guiding channels

Step 8: Adding protective coverings and guiding channels top shell to harness bundle

Here in below figure, we have done with whole wiring harness routing for the V16 Engine. Now, we have to add protective coverings to all bundle segments and top shell of the guiding channel.

In above figure, we have added 10mm slit COT tubes on top of the bundle segments as a protective covering. We have assumed start and end extremity for the COT tubes approximately.

In above figure, we have added 7mm Cotton tape on all the bundle segments connecting to the all 20 connectors.

In above figure, we have added all the slit COT tubes and cotton tapes on bundle segments as a protective coverings. Also, we have added top of the both left and right side plastic guiding channel.

Step 9: Checking bundle continuity

In this step, first we have to make sure that multi-branchable is selected then we have to go in Edit>Search>Advanced>Workbench-Electrical>Type-Bundle Segment>Attribute-Fully Connected

• By selecting 'FALSE' option will show all the connected bundle segments while selecting 'TRUE' option will show all the non-connected bundle segments.
• Here, we have selected for the 'FALSE' option and searched for results. All the bundle segments are highlighted found showing that all the bundle segments are electrically connected as shown in below figure.

Step 10: Creating flatten view of the engine harness geometrical bundle assembly

In this step, for creating flatten view we have to work in Electrical Harness Flattening workbench of Catia V5. We should also make sure that the flattening file is saved in the same folder where other files of harness assembly are saved

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• Before creating flatten view, first we have to define flattening parameters. Make sure that selecting 'Single line' for bundle segment and 'Double' line for protective covering.
• We have extracted the bundle assembly into Engine Harness Flattening Product file and then flattened the file along face of interconnection connector as shown in above figure.
• At this stage, for clarity, we have been hidden the flattening diagram of the plastic guiding channels from the drawing view.

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Step 11: Creating a flatten view drawing for the wiring harness assembly

• In above figure, we are creating new drawing file and defined all the necessary drawing parameters. We have to insert the front view of the Engine Harness Flattening Product file into the Drawing file.