Project 1

Route the Wiring harness on Given Engine and Prepare flattened 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.

Available connector 3D data can be used, or you can download the connectors from www.te.com

Prepare & Submit all necessary reports like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity, and Assumptions if any along with CATIA 3D data.

Ans:

STEP 1:

Create a new product in assembly workbench named "assembly wiring harness context" and add the V16 engine CAD data inside this context assembly. now mark the region for installation of the connectors. The region for sensor placement are marked in blue. the different connectors required are

1) 16 Connectors for injectors

2) 4 connectors for cam shaft

3) 1 coolant sensor 

4) 2 engine oil temp and pressure sensor

5) 1 vehicle speed sensor

6) 1 neutral sensor

7) 1 Interconnection connector

STEP  2:

Download the 3D data of required connectors and its mountings from the site www.te.com and import them into CATIA V5. Define the electrical properties by going to electrical part desing workbench and create the bundle conncection pont and cavity connection point

STEP 3: 

Define  the mounting clip electrically by defining all the properties .Define the clip as mounting equipment using mounting equipment command. Select cavity command and define the parameters. Then create an assembly and mate both the clip as well well as the connectors using appropriate tools.

STEP 4:

Define other guiding devices electrically for P clamp and fir tree clip we need to use define the equipment option and then provide entry, exit and base plane, then define them electrically using define support part in the electrical part design workbench.

We will be using a plastic guiding channel at the injector connector region as they are close to high heat generation area of the engine.                 we have to use define equipment option and then define the  bundle connection point each individual opening as well as the main entry for routing the wire through them.

STEP 5: 

Insert all the connectors, clips, clamps and necessary parts for routing the wire and arrange them properly.  Place P clamps and fir tree clip wherever necessary based on the logics (the main purpose is to avoid slag and extra loose matrerial might get damaged while the engine is vibrating)

STEP 6:

To mirroring the guiding channel double click on the desired part , select mirror option then select part body( from the drop down menu) and select appropriate axis from the part level and click ok. a mirror image is created

STEP 7:

Switch to the electrical harness assembly workbench and electrically define the geometrical bundle using the "Define Geometrical Bundle" option. Start the bundle routing using the "Multibranchable" command and define the bundle routing path from the interconnection connector to various components, including P-clamps and guiding channels. Route the harness completely and use adittional mountings if any additional requirement is felt.

STEP 8:

Add protective coverings, such as corrugated tubes, to protect the wiring harness from high temperatures and hazardous liquids.

STEP 9:

Check the bundle continuity to ensure that all segments are fully connected.  Follow the design criteria for harness routing, considering factors like manufacturing ease, accessibility, removal, and maintenance of attached equipment, avoidance of sharp environments, clearance requirements, slack management, and harness protection.

Step 10: 

Flatten the wire harness by going to electrical flattening workbench, select harness flattening parameter, keep the product to be flattened opened in a new window. Click on the extract button and click on the context assembly where multibraching is done now we can see that the harness assembly gets exported, click on the flattening command and select the connector face on active plane and select all bracnhes. The model is flattened.

STEP 11:

To create a flatten view drawing of the wiring harness by creating a new drawing select the front view go back to flattened model and select the surface then flattened 2D view is obtained on the sheet left click to confirm the view. then save the drawing as image.