Project 1

AIM

Route the Wiring harness on Given Engine and Prepare flatten view drawing in CATIA V5. Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply Protection coverings as required.

Engine wiring harness routing

The above figure shows the given V16 engine cad data. Here routing the wiring harness for the following electrical components attached to the engine.

• We have 16-cylinder engine camshaft sensors on each engine block (4 camshaft sensors) Engine coolant sensor in the centre of the engine between the two blocks
• Engine oil temperature and pressure sensors installed in the engine's oil sump on both engine cylinder blocks sensors for sensing neutral position of the transmission assembly and measuring vehicle speed
• Connects the engine harness system to the vehicle harness system through an interconnection link.
• Harness installation and routing management are essential for effective wire harness packaging. It also addresses clearance management and manufacturing capability.

Geometrical bundle contains all of the harness components i.e connectors, clip, gromets and actual physical bundle segments and branches. All the components should be defined electrically.

Download the 3d data of required connectors and mountings from the site www.te.com

In catia component design workbench, access the connector cad data and build the connector connection point, connector connection axis system, and bundle connection point. Then Change to the electrical part design workbench and specify it as a connector, as well as the connector connection point and the bundle connection point.

We have an interconnection connector here that requires a mounting clip to be mounted.

As a result, a cavity connection point for this connector should be defined.

All connectors are defined as electrical connectors, and all connector attributes are described.

In the connection family, I created a catalogue document and stored all of the connector data in it.

download the other harness mountings like clips and clamps cad data. Also download the brackets for parking the interconnection connector and channel for routing the harness in high temperature zones

Mounting clip

Define the clip as mounting equipment using mounting equipment command. Select cavity command and define the parameters.

Fir tree clip

First define geometrical parameters such as entry point, entry plane, exit point, exit plane and base plane. Then switch to electrical part design workbench and define the fir-tree clip as support using support command and define the parameters.

Plastic guiding channels

The given V-16 engine has 8 injectors both on the left and right side of the engine which are close to one another, so plastic guiding channel is used for trouble free routing of the wiring harness in addition it provides thermal protection from high temperature zones of the engine.

First create geometrical parameters such as bundle entry points, and external reference line in the part design workbench to route the wiring harness into the guiding channel then define the guiding channel as an electrical part by using the define equipment option. define all the properties to the channel.

Sheet metal bracket

Add sheet metal bracket in order to provide parking 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.

• Add all the electrically defined components to the geometrical bundle. Place the components at proper location for routing the harness
• Then switch into the electrical harness assembly workbench and Geometrical bundle product file should be electrically defined using the Define Geometrical bundle option.

Harness routing and packaging

• The available connectors are added into the geometrical bundle and properly positioned onto the fuel injectors, camshaft sensors, vehicle speed sensor, neutral position sensor and engine coolant sensor. Manipulation tool is used to place the connectors.
• Here we have one interconnection connector to connect engine harness system to vehicle harness system.so it required additional parking provision. Existing bolt on the engine is used to mount the sheet metal bracket. The bracket should be provided with a suitable locking feature in clockwise direction. First mount the clip on the sheet metal bracket. Then the interconnection connector is electrically connected with the mounting clip by using connect electrical devices command in the electrical assembly design workbench.After finalization of the routing, request the Engine design team to provide the threaded holes for fix the Fir tree clips as per their location.

Harness routing

• Add protective coverings on the wiring harness to protect wiring from high temperature. protective covering created by using define protection part command in the electrical part design workbench. Select part, and define the parameters as per the requirement.
• The created corrugated tube can be added into the catalogue by store device command and selecting the catalogue file created for protective covering. then appropriate protective covering added to the bundle segments.

After routing the harness then check the bundle Continuity.

Edit⮕Search⮕Advanced⮕Electrical Workbench⮕Type:-Bundle Segment⮕Attribute:-Fully Connected.Selecting the "TRUE" option in the attribute criterion it will show all the connected bundle segmen

Design criteria followed to route the wiring harness

• Wiring harness routed by considering the factors ease in manufacturing, accessibility, easy removal and easy maintenance of attached equipment’s and routing harness.
• Wiring harness should be routed in such a way that it is easy to assemble on a vehicle.
• Wiring harness should be kept away from sharp environments like sheet metal brackets, panel edges, corners etc.
• Avoid harness routing and clipping in blind zone of operator during harness during installation.
• Ensure that routing meets the clearance requirements with the different surrounding parts.
• Routing shall provide enough slack for each branch to avoid additional stress on wire and terminal crimping joints but ensure that extra slack does not cause wiring harness foul with surrounding parts and impact desired clearance requirements.
• Enough clamps should be provided to ensure the positive clearance with surrounding and safety of wiring harness.
• Use of plastic guided channels are recommended to meet the clearances in critical areas if it is difficult to achieve by use of clamps.
• Branch length should be minimum 50 mm.
• Minimum distance between clip and nearest branching point should be 25 mm.
• Minimum distance between two breakouts should be 50 mm.
• Limit the no. of branches from single branch point up to 4.
• Ensure that harness protection is provided according to surrounding temperature, manufacturability and expected reliability.
• The min. bend radius is to be 1.4.

Wiring harness flattening

Create a new product file for flatten the wiring harness and save as in the same folder where the wiring harness is saved. Then switch to Electrical harness flattening workbench and select harness flattening parameters and define harness flattening parameters. Before creating flatten view, make sure that selecting 'Double line' for bundle segment and 'Double' line for protective covering.

Drawing of the flattened wiring harness

To produce drafting of the harness, start a new drawing file and pick the front view command, then go to the flattened harness window and select an appropriate face.

To make the bundle segments visible, right-click on the drawing sheet and select properties. In the display tab, select '3D wireframe' and 'is always visible' in the dress up settings.

V-16 Engine Catalogue