Project 1

PROJECT 1

Aim:- To route the Wiring harness on given engine and prepare flattened view drawing in CATIA V5. 

Modeling:-

To start with, first and formost thing is to download the 3D data from given link and www.te.com. Then, the parts (connectors, clips and clamps) are to be electrically defined and stored in appropriate catalogues (in catalogues for connectors as well as for clips and clamps). These are done as shown below:-

The engine part file is also downloaded from the link.

A product file for Engine Harness Context assembly is created. In that the engine product as well as geometrical bundle is added for wiring harness routing as shown below:

Now we have to place connectors for injectors, camshaft sensors, transmission sensor, neutral sensor and engine coolant temperature sensor on the engine. For injectors, 4 pole connectors are used which are in a total of 16. For camshaft sensors also, 4 pole connectors are used which are 4 in number. The connectors used for coolant temperature sensor, neutral and transmission sensor, 2 pole connectors are used.  This is done as shown below:

Thus connectors are put in place.

Now, we can assume a convienient position for the interconnection of chassis wiring harness with engine wiring harness. For the interconnection to be positioned, a land is required, for that purpose a 'L' bracket is created and postined as shown below:

 As a part of wiring harness planning, some P Clips are added for better arrangement of harness bundles. However they may be manipulated if required.

For injector connectors, guiding hannels are to be provided to the harness bundle, to ensure safe and smooth continuity of the bundle. For that, guiding channels are created as bottom and top covers, and put in place as shown in the below figure. The fixations are to be ensured because there are no provisions for fiaxation on the side face as per now.

 Before starting routing, some furr tree clips are also added in order to ensure smooth continuity of the harness bundle.

The wiring harness routing have been done as shown below. Necessary arrangements have made on the placements of clips and clamps for proper routing:

Peotection coverings are also added into the wiring harness routing leaving adequate gap at both extremities:

 Checks for bundle continuity was done and favourable results were obtained as follows:

 For flattening, flattening product is made and geometrical bundle is flattened as shown below:

Since the routing is complex, we can't simulate the actual shape into flattened structure. The drawing file of flattened product is also created as shown below:

Critical checks like clearance of the bundle, fouling of bundle with edges, bundle continuity, minimum bundle length,.... etc are checked and is found OK. Application of all Packaging rules, Industry best practices studied have been used in design.