Project 1

WIRING HARNESS FOR ENGINE

AIM:

• To route the wiring harness for the given engine.
• Application of all Packaging rules, Industry best practices studied in this course shall be demonstrated in design.
• Apply Protection coverings as required.

INTRODUCTION:

WIRING HARNESS OR CABLE HARNESS:

A cable harness, also known as a wire harness, wiring harness, cable assembly, wiring assembly, or wiring loom, is an assembly of electrical cables or wires which transmit signals or electrical power. The cables are bound together by a durable material such as rubber, vinyl, electrical tape, conduit, a weave of extruded string, or a combination there of.

Cable harnesses are usually designed according to geometric and electrical requirements. A diagram is then provided (either on paper or on a monitor) for the assembly preparation and assembly.

The wires are first cut to the desired length, usually using a special wire-cutting machine. The wires may also be printed on by a special machine during the cutting process or on a separate machine. After this, the ends of the wires are stripped to expose the metal (or core) of the wires, which are fitted with any required terminals or connector housings. The cables are assembled and clamped together on a special workbench, or onto a pinboard (assembly board), according to design specification, to form the cable harness. After fitting any protective sleeves, conduit, or extruded yarn, the harness is either fitted directly in the vehicle or shipped.

OBJECTIVE

• Define all the mechanical connectors electrically and save it in the Catalogue.
• Place all the connectors to the required positions on the given engine 3D CAD model
• Place P-Clamps and Fir Tree clips at the required position by following the packaging rules.
• Create the Wiring Harness Routing with all the electrically defined connectors and mounting equipments.
• Create branching points at required locations to create sub branches and connect to various connectors in the geometrical bundle.
• Apply Protection coverings as required.
• Create Wiring harness flattening for the final geometrical bundle.
• Using the drafting workbench, create a drawing sheet with the flattened wiring harness.

DESIGN METHODOLOGY

Step 1- download the engine CAD data and required connectors CAD data from the given source.

Step 2- Download the required Connectors from the source and convert the mechanical connectors electrically by using the electrical part design work bench by following below steps.

• First download the connectors and mounting clip from the given link source.
• Get into the mechanical part workbench to create required geometrical parameters. Create connector connection point and bundle connection point on the required sides of the CAD part.
• Create axis system on the connector connection point such a way that the Y coordinate facing normal to the connector face, X coordinate facing towards the locking mechanism and Z coordinate facing to the top.
• Create cavity connection point for connectors having the cavity for mounting clips

Using the geometrical parameters created,

• Define part as electrical connector.
• Define bundle connection point.
• Define connector connection point.
• Define cavity connection point.

Step3- Adding connectors to all 16 fuel injectors sensor :-

All the connectors have to be added inside the Engine harness geometrical bundle assembly. Manipulation tools along with a compass, snap, and smart move features should be used to locate all the 16 connectors in their desired locations. 

First, connectors are located for the first 8-fuel injector sensors which are on the left side of the engine. At last, the remaining 8 connectors are added to the 8 fuel-injectors on the right side of the engine.

Step3- Adding Interconnection connectors sensor :- 

Defining the Interconnection connector and mounting clip electrically and then mounting it on the created bracket. Mounting P clamps for wire harness.

A 12-pole "C-776438-4" connector and mounting cavity "C-1924487-2" is used as an interconnection connector. The 3D-CAD data file for the required connector and the cavity is downloaded from TE.com. Both the connector and the cavity are electrically defined and mounted on the sheet-metal bracket.

Plastic Guiding Channel

The V16 engine has 8 fuel injectors on the left side and 8 fuel injectors on the right side of the engine. All these fuel injector sensors are located very close to each other. So, the best way to route the wires around them is by using a plastic guiding channel as they will help us organize all the wires very precisely and will reduce complex wiring harness routing. To mount the plastic guiding channels we would need some mounting provisions. The engine design team can be consulted and asked to provide mounting threaded holes or threaded bosses.

There will be two different plastic guiding channels for this engine. One for the left and theother for the right side of the engine. It has to bemade sure that proper clearance (at least 50mm) is provided between the plastic channel andthe exhaust pipes. The total thickness of thethese channels is 25 mm.

The plastic guiding channel will be a two-piece molded plastic that will protect the wiring harness from surrounding high temperatures, wear and tear while providing nice aesthetics to the engine.

 Locating the Guiding channel:-

 Use manipulation, compass, snap and smart move commands to locate and move the guiding channels in place as shown below. These channels are added inside the engine harness geometrical bundle. At this stage, we will only add the bottom part of the left and right guiding channels.

PACKAGING RULES:

• Wiring harness routing shall provide ease in manufacturing, accessibility, easy removal, and easy maintenance of attached equipment and wiring harness.
• Routing through small structural holes and openings shall be avoided, minimize chaffing and handling of the wiring harness during installation.
• Avoid the harness routing and clipping in the Blind zone of the Operator during harness assembly or in service.
• Routing shall offer protection against possible damage through common misuses such as being handhold and temporary support for test equipment.
• Provide additional slack to the harness according to the surroundings and harness bending requirements.
• Ensure the routing meets the clearance requirements with different surrounding parts.
• Avoid routing over the bolts, near to the bolted joints. It may damage the harness or puncture the harness. Keep harness away from panel mounting screws.
• Avoid harness routing near sharp edges, if not possible provide protection to the harness.
• The maximum distance between two clips on a straight branch is 200mm.
• Provide Clips and clamps if the harness is going to bend at multiple locations.
• The use of too many sheet-metal brackets should be avoided.
• The branch length should be more than 50 mm.
• Min distance between clip and branching point to be 25 mm.
• Min distance between two branch breakouts should be 50 mm.

 Checking Bubdle Continuity:-

First, we have to make sure that multi branchable is selected and then we have to go in WORKBENCH>TYPE-BUNDLE

EDIT>SEARCH>ADVANCED>ELECTRICAL

SEGMENT>ATTRIBUTE-FULLY CONNECTED

Selecting the "TRUE" option will show all the connected bundle segments while the selecting "FALSE" will show all the non-connected bundle segments.

For now, we will select "TRUE" and search for results. All the bundle segments are highlighted and found showing that all the bundle segments are electrically connected.

FLATTENNING

• In above figure, we are creating new drawing file and defined all the necessary drawing parameters. We have to insert the front view of the Engine Harness Flattening Product file into the Drawing file.

Conclusion:

In this way, we have routed wiring harness for the Bugatti V16 Engine. Also, prepared flatten view drawing with proper sheet in CATIA V5.  

Google Drive Link: https://drive.google.com/file/d/1mCNoX2ETvUw-bU26Zj04QHfRIZGMQ8Nw/view?usp=drive_link

Note: Due to barrier of 20 MB file submission I am unable to submit my project file of dashboard. So kindly check the link and grade my Project 1.