Project 1

Statement of assignment:

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.

• Fuel injector for each cylinder we have 16 cylinder engine.
• Camshaft sensors on each engine block (4 camshaft sensor ).
• Engine coolant sensor at the centre of the engine between the two blocks.
• Engine oil temperature and oil pressure sensor fitted at the oil sump of the engine on both engine cylinder blocks.
• Sensors for sense neutral positon of the transmission assembly and measure the vehicle speed.
• Interconnection connector to connect engine harness system to vehicle harness system.

Harness mounting and routing management required to provide proper packaging of the wiring harness.it also deals with clearance management and manufacturability,

• P-clamps to provide positive clamping and proper clearance management for the routing.
• Mounting clips for connector mounting.
• Guiding channels provide thermal protection in high temperature zones.
• Corrugated tubes used to protect the wiring harness from hazardous liquids and temperature.

Next create a new product in assembly workbench named as assembly wiring harness contex .it is the top level product file inside this product file created geometrical bundle and wire harness electrical bundle.Given V16 engine cad data added inside this contex assembly.

Geometrical bundle contains all of the harness components i.e connectors ,clip, grommets 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

GIVEN REQUIREMENTS

Connector 12 POLE

2 POLE CONNECTOR

CLIP

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

BOTTOM CHANNEL

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 inaddition it provide thermal protection from high temperature zones of the engine.

FURR TREE CLIP

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 fur-tree clip as support using support command and define the parameters.

L CLAMP

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.

P CLAMP

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 P-clamps as support using support command and define the parameters

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.

Adding supporting components like p-clamps and fir-tree clip . P-Clamps are mounted on the existing bolts and screws to provide positive clamping and ensure proper clearance management for the wiring harness routing and also help to prevent the harness fouling from unwanted mechanical components.

P - Clamp and the Fir Tree can be placed at appropriate location and ensure clearance management.

Add guiding channel for routing the wiring harness to the fuel injectors.it deals with clearance management and thermal protection of the wiring harness in the high temperature zones.Then request engine design team to provide additional threaded holes required to mount the guiding channels in proper location by using bolts or screws .

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 equipments 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 50mm.
• Minimum distance between clip and nearest branching point should be 25mm.
• Minimum distance between two breakouts should be 50mm.
• Limit the no. of branches from single branch point upto 4.
• Ensure that harness protection is provided according to surrounding temperature, manufacturabilty and expected reliability.
• The min. bend radius is to be 1.4.

MULTI BRANCHABLE

ELECTRICAL CONTINUITY

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.