Project 1

                                                           REPORT ON FINAL PROJECT 1

AIM

The aim of this project is to 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.

WIRING HARNESS ROUTING OF ENGINE:

• Engine is taken to route the wiring harness. The engine modeller will provide the dummy connectors at all the locations.
• First check for all the connector and sensor locations. The present engine has 8 connector location on each side and 2 sensors at each side.
• The clips, clamps and channels can be used to route the harness with optimal solution.
• Also, there are 4 cam-shaft sensors, so there is total 20 sensors that we have to connected electrically.
• Generally, 4-pole connectors are used for fuel injectors of the engine.
• The engine will also have an interconnection connector which will connect the engine to other parts of the vehicle. We will be using a 12-pole electrical connector with a mounting clip feature as an interconnection connector.
• The plastic guiding channel used in this harness should be made of a material that can withstand at least 150 degrees Celsius.
• The bend ratio for the all-bundle segments should be 1.4 . 

Assumptions:

1. Provide clips/clamps as per requirement.
2. Make sure that there is no any fauling case while designing the wire harness. Additional clips/clamps may be used to avoid fauling case.
3. Give additional slack if needed. 5-10% slack is sufficient.
4. Avoid routing over bolt and bolted joints to avoid harness puncture.
5. Avoid routing on sharp edges or else provide protection over the harness.
6. Follow the clearance distance and keep away the harness from heat generation components.
7. Protection should be provided as needed according to surrounding temperature.
8. Avoid direct support for harness on fuel lines routed in the engine.
9. Use plastic guiding channels if needed.
10. Branch length should be greater than 50mm.
11. Minimum distance between two branch points should be at least 50mm.
12. Minimum distance between clip and branch point should be at least 25mm.
13. Avoid too many sheet metal brackets on the engine. Try to use available threaded bosses on the engine or demand for it.
14. The wiring harness should be easy to assemble and easy to access. 
15. While using dummy connectors, ensure that whatever positions you are defining that are practical. Bundle diameters and another placements can be defined properly for the wire harness routing.
16. If the packaging area is too tight and there are many packaging constraints then we can think of creating harness channel which can be used to route and protect the wire harness effectively.

WIRING HARNESS DESIGN METHODOLOGY

• Creating wiring harness context - 

create a product file named as Engine harness context and put the engine part inside that product file and also create a product inside context and named as geometrical bundle. Add the L Clip into the context.

Now convert all the connectors, clips and support part as electrical component and put them inside the geomterical bundle.

12 pole connector - 

4 pole connector - 

3 Pole Connector - 

2 Pole Connector - 

P-Clamp - 

Furr Tree Clip - 

Buttom Channel Left - 

Buttom Channel Right - 

• Harness Routing and Packaging

Go to the Assemble Workbench and positioned all the connectors, clips & clamps and support files at the required position.

8 injector connector left

8 injector connector right

4 camshaft sensor connector

2 oil temperature senser connector

1 coolant temperature senser connector

1 neutral indicator connector

1 speed senser connector

p clamp, Furr Tree clip & Channel

Now go to the Wiring Harness Workbench and create wiring harness routing bundles - 

Add Upper Covering for Channel - 

Now check for the Continuty of harness bundles - 

Now Add the Protective Covering on the Harness Bundles 

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.

Now flatten the harness bundles using flatten command - 

Now we create a new drawing file for Flatten Product -

CONCLUSION

We have discussed about wiring harness design and routing & design methodology. Then we have created wiring harness for Engine and also flatten the harness bundle and create the drawing file. 

PROJECT FILE IS ATTACHED IN THE BELOW LINK BECAUSE DUE TO THE MORE SIZE OF THE ASSEMBLY FILE.

https://drive.google.com/drive/folders/1svJ0fZK86WBLpEIdcyenDyyKBiqAXFYY?usp=sharing