Project 1

Objective

The objective of the project is to route the wiring harness on given V16 Engine and prepare flatten view drawing in CATIA V5. All types of packaging rules have to be considered while routing the harness. Also, Industry best practices should be demonstrated in design. All the necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design wiring harness.

• The above figure shows the 16 valve Engine where 8 cylinders are placed on the right side and 8 cylinders are placed on the left side.
• There is total 16 injectors where 8 injectors are used for 8 cylinders on right side and 8 injectors are used for another 8 cylinders on left side.
• Also, there are 4 cam-shaft sensors, so there are 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 material that can withstand at least 150 degree 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 failing case while designing the wire harness. Additional clips/clamps may be used to avoid failing case.
3. Give additional slack if needed. 5-15% slack is sufficient.
4. Avoid routing on sharp edges or else provide protection over the harness.
5. Follow the clearance distance and keep away the harness from heat generation components.
6. Protection should be provided as needed according to surrounding temperature.
7. Avoid direct support for harness on fuel lines routed in the engine.
8. Use plastic guiding channels if needed.
9. Branch length should be greater than 50mm.
10. Minimum distance between two branch points should be at least 50mm.
11. Minimum distance between clip and branch point should be at least 25mm.
12. Avoid too many sheet metal brackets on the engine.
13. The wiring harness should be easy to assemble and easy to access. 
14. While using dummy connectors, ensure that whatever positions you are defining that are practical. Bundle diameters and other placements can be defined properly for the wire harness routing.
15. 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.

 COMPONENTS USED

12POLE CONNECTOR

4 POLE CONNECTOR

2 POLE CONNECTOR

FIR TREE CLIP

L_CLIP

P_CLAMP

 PROCEDURE TO ASSEMBLY PRODUCT:-

Step 1: Creating Context Assembly

A Context Assembly for Engine Harness has created which will work as the main assembly as shown in above figure.A Context Assembly will contain Engine Assembly data for V16 Engine and Engine Harness Geometrical Bundle Assembly.If any sheet metal bracket will require then they are added in the context assembly.

Step 2: To define 4-pole connector electrically

We have to define all the connector that is 2 pole, 3pole, 4 pole and 12 pole interconnection connector as an electrical part by define as connector connection point and bundle connection point. (ALL THE CONNECTORS IMAGES GIVEN BELOW)

Also define the clip and channels that is needed as an electrical part.

Step 3: Adding connectors to the all 16 fuel injector sensors and 4 cam-shaft sensors

In this step, we are placing connectors to fuel injector sensors and cam-shaft sensors. So we will require total 20 connectors which have to be added in the Engine Harness Geometrical Bundle Assembly. We have to use manipulation tools along with compass, snap and smart move features to locate all the 20 connectors at their desired locations.

Step 4: Adding sheet metal bracket

we need to add the sheet metal bracket which is L-clip to the Harness assesmbly. 

Step 5: Mounting the interconnection connector on the sheet metal bracket and mounting the p-clamps for wire harness

Interconnection cnnector is the major connector for wiring harness to the engine. it needs to be firmly fixed to the bracket using clip for better rigidity.

Step 6: Mounting of a plastic guiding channel

Guiding channel is to provide pathway as well as safety feature for the wiring harness to the fuel injectors from exhaust and engine heat and also from external physical damages.

 

Step 7: Bundle routing from Interconnection connector to 3 P-clamps

Wiring between Interconnection connection to the P-clamps are completed.

Step 8: Routing to the plastic guiding channel

Routing to the 8 injectors on both sides using Guiding channel with proper wiring parameters.

Also Adding branch points to bundle segment inside the guiding channel

(Engine is hided to show the wiring)

 

Step 9: Adding protective coverings and guiding channels top shell to harness bundle

 Default End extremity is taken as 30 mm to all the connectors and respective Corrugated tubes of diameter 5mm,10mm,15mm are used respectively.

Step 10: Checking bundle continuity

To check,go to Edit -> Search -> Advanced -> select workbench as 'ELECTRICAL' -> Type as 'BUNDLE SEGMENT' -> Attribute as 'FULLY CONNECTED' -> 'FALSE' -> click search icon. This will show the results of discontinued bundle segments from main wiring harness. When there is nil, Our circuit is single piece harness and good to go.

Step 11: FLATENNING AS DRAWING

 Below is the Flatenned drawing of the wiring harness.

 Conclusion

The Project in which routing the wiring harness on given V16 Engine and prepare flatten view drawing in CATIA V5 is completed considering all types of packaging rules for  routing the harness.