Project 1

AIM

Route the harness on given V-16 engine and prepare flatten view. Apply all packaging rules and industry best practices for the given engine.

Engine harness

An engine wiring harness is constricted wires, cables, terminals, and connectors controlling a vehicle’s electrical system. It relays electrical power and control information to components such as batteries, alternators, fuel injectors, fuses, audio systems, blower motors, fuel injectors, and computers. Wire harness companies customize it for every location, application, and design it interconnects.

Design considerations

1.While routing wires through engine we need to take care of the temperature of the engine part and the melting point of the wire inorder to avoid melting. For that we can use some protection material which helps to avoid the direct contact of wire with engine.

2.Distance between two branch points should be minimum 50mm.

3.Distance between clip and branch point should be minimum 25mm.

4.Distance between clip and branch point should be at least minimum 25mm.

5.Harness should be routed in such a way that it is easy to assemble on a vehicle.

6. Harness should be kept away from sharp environments like sheet metal brackets, panel edges, corners inorder to avoid mechanical defect called chaffing.

7. Avoid harness routing and clipping in blind zone of operator during harness installation to ease the installation process.

8. Ensure that routing meets the clearance requirements with the different surrounding parts according to the design/routing rules of harness.

9. 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.

9. Enough clamps should be provided to ensure the positive clearance with surrounding and safety of wiring harness.

10.Use of plastic guided channels are recommended to meet the clearances in critical areas if it is difficult to achieve by use of clamps.

11. Give some extra lenth to repair the routing if some damage happened on the wire. This extra lentgth will help to ensure the repairing easy. No need to add splice and no need to replace damaged harness.

Flattening

Flattening is done to measure the actual length of the harness to be manufactured, so that we can install it in to the required position. Falttening also will give us the clear picture of the harness to be installed on the component.

Conclusion

Thus the engine harness routing is done according to the design rules and flattening drawing is created.