Project 1
Solution
Aim
Route the wiring harness on given engine and prepare flattened view drawing in CATIA V5. Application of all Packaging rules, Industry best practices studied shall be demonstrated in design. Apply protection coverings as required.
Engine Wiring Harness Routing
The V16 engine CAD data is seen in the image above. The wire harness for the following engine-attached electrical components is routed here.
• Each of the 16-cylinder engines has a fuel injector.
• There are four camshaft sensors on each engine block.
• Engine coolant sensor between the two blocks in the middle of the engine.
• Engine oil temperature and pressure sensors are installed on both cylinder blocks' oil sumps.
• Sensors that detect the gearbox assembly's neutral position and gauge vehicle speed.
• An interconnection connector to link the vehicles and the engine's harness systems. It is necessary to mount the wire harness and manage its routing to ensure suitable wiring harness packaging. Additionally, clearance management and manufacturability are addressed.
P-clamps to offer effective routing clearance management and positive clamping.
Corrugated tubes are used to shield the wiring harness from potentially dangerous substances and temperatures.
Mounting clips for mounting the connectors.
Guiding channels provide thermal protection in high-temperature zones. Next, make an assembly wire harness context new product in the assembly workbench. The wire harness electrical bundle and geometrical bundle are constructed inside of this product file at the top level. Given that this context component now has V16 engine CAD data. All of the harness parts, such as connectors, clips, grommets, and actual physical bundle segments and branches, are included in the geometric bundle. Electrical definitions should be given to each component. Download the necessary connections and mountings 3D data from the website www.te.com
Define all of the Geometrical and Electrical Properties of the Connectors as given in the Figures Below
Connector No. 1 (Interconnection Connector)
Connector No. 2
Connector No. 3
Connector No. 4
Connector No. 5
Create the connector connection point, connector connection axis system, and bundle connection point by opening the CAD data for the connectors in the CATIA component design workbench.
Then enter the connector definition in the electrical part design workbench along with the connector connection point and bundle connection point. Here, we have an interconnection connector that needs a mounting clip to be mounted.
Therefore, the cavity connection point for this connector should be defined (for connector No. 1). Every connector has been identified as an electrical connector, along with all of its necessary properties.
A catalog document is made in the connector family, and it is used to contain all of the connector data, as shown below.
Download the CAD files for the other harness mountings, such as clamps and clips. Additionally, download the channels for routing the harness in high-temperature zones and the brackets for parking the interconnection connector.
Mounting Clip
The definition of each geometrical property of the mounting clip will allow you to electrically define it. Use the mounting equipment command to define the clip as mounting equipment. Choose the cavity command and provide the necessary parameters.
P-Clamp
Define geometrical parameters first, such as the base plane, exit plane, and entry plane. The P-clamps are then defined as support using the support command and the parameters set in the electrical part design workbench.
Fir Tree Clip
Define geometrical parameters first, such as base plane, entry point (and plane), and exit point (and plane). Then, move to the electrical part design workbench, and define the fir tree clip as support. After that, identify the wires (or bundle) entry, base, and exit planes. Two entries and exits should be available. Therefore, define the second entry and exit.
Plastic Guiding Channels
The supplied V-16 engine has 8 injectors that are close to one another on both the left and right side of the engine. Therefore, plastic guiding channels are employed to ensure that the wire harness is routed without incidents. Additionally, it offers thermal protection from engine areas with high temperatures. To route the wire harness into the guiding channel, first, create geometric features such as bundle entry points and an external reference line in the part design workbench. Then, using the identified equipment option, designate the guiding channel in the workbench as electrical equipment.
Sheet Metal Bracket
To provide parking for the interconnection connector, add a sheet metal bracket. Additionally, we must ensure that the bracket is positioned outside of the engine and geometrical bundle assemblies and inside the context assembly because it is not used as an object for bundle routing.
Placement of Connectors
Switch to the “Assembly Design” workbench, and start placing the connectors at the proper location using the snapping features and compass.
Place the 4-pole Connectors at the 16 Fuel Injector Sensors.
Place the 4-pole Connectors at the 4 Camshaft Sensors.
Place 2-pole Connectors on the Coolant Temperature and Vehicle Speed Measurement Sensors.
Coolant Temperature Connector
Vehicle Speed Measurement Connector
Place Connector No. 2 on the Neutral Sensor.
Place the L-sheet Bracket and the Interconnection Connector in the Desired Suitable Position to Assist in the Wiring Harness and Routing.
Place the L-sheet bracket in a suitable location, to place the interconnection connector on it. Note that you need to connect the mounting clip electrically to the interconnection connector before being placed on the L-sheet bracket.
Place the P-clamps on the Desired Suitable Position to Assist in the Wiring Harness and Routing.
Place Fir Tree Clips on the Desired Suitable Positions to Assist in the Wiring Harness and Routing.
Guiding Channel
For the electrical wiring to be connected to the fuel injectors, provide a guiding channel on both sides. These channel deal with the thermal shielding provided by the wiring harness at high-temperature zones and clearance control. Then ask the engine design team for more threaded holes so you can use bolts or screws for installing the guiding channels where they need to be.
Harness Routing and Packaging
• Include all of the electrically defined components in the geometric bundle. Place the parts in a way that allows the harness to be routed through them.
• Use the “Geometrical Bundle” command on the electrical harness assembly workbench to electrically specify the geometrical bundle product file.
• The geometric bundle contains the accessible connectors that are correctly mounted on the fuel injectors, camshaft sensors, engine coolant sensors, and camshaft sensors. A manipulation tool is used to position the connectors.
• The interconnection connector is where the bundle routing begins, followed by the P-clamps and guiding channels. Add branch points to direct the wire harness from the main branch to different connectors.
• Choose the external curve option, then click on the line that has been drawn in the guiding channel to route the wiring harness through it. After that, add branch points to the wiring harness to direct it to the connectors from the guiding channel. To prevent tension on the wire, the bundle section is given the necessary bend radius and slack.
• To shield the wiring from high temperatures, add protective coverings to the wiring harness. The "define protection part" command in the "electrical part design" workbench creates a protective covering
• By using the “Store Device” command and choosing the catalog file prepared for protective covering, the created corrugated tube can be added to the catalog. Then, the bundle segments are given the proper protective coatings keeping 15mm distance from each connector.
• Verify the Continuity of the Bundle after Routing the Harness.
Electrical Workbench Edit > Search > Advanced > Type: Fully Connected is a bundle segment attribute. When the attribute criterion's "FALSE" option is used, all of the corresponding bundle segments are displayed.
As can be illustrated, all the bundle segments are fully connected
Design Criteria to Follow for Routing the Wiring Harness
The routing of the wiring harness took into account variables including ease of manufacturing, accessibility, convenience of equipment attachment and maintenance, and ease of equipment removal.
The wiring harness should be laid out so that it is simple to install on a vehicle.
The wiring harness should be routed and maintained away from sharp surfaces such as panel edges and corners.
When installing the harness, avoid routing and clipping in the operator's blind zone.
Verify that the route satisfies the conditions for clearance with the various adjacent parts.
When routing, each branch must have adequate slack to prevent further strain on the wire and terminal crimping joints, but the extra slack must not interfere with neighboring components or reduce the desired clearance requirements.
Enough clamps should be available to guarantee the wiring harness's safety and positive clearance with the environment.
If using clamps to satisfy the clearances in crucial sections is challenging, then the use of plastic guiding channels is recommended. The minimum branch length should be 50mm.
There should be a minimum of 25mm between the clip and the closest branch point.
There should be a minimum of 50mm between two breakouts.
Check to see that harness protection is offered by the local temperature, manufacturing potential, and expected reliability.
A minimum bend radius of 1.4 is required.
Wiring Harness Flattening
To flatten the wiring harness, create a new product file and save it with the desired name in the same folder as the wiring harness. Then, select “Harness Flattening Parameters” and define harness flattening parameters on the “Electrical Harness Flattening” workbench. Make sure to select “Double line” for the bundle segment, and “Double line” for the protective covering when defining the harness flattening parameters before producing the flattened view.
Flattened View
Drawing of the Flattened Wiring Harness
To generate a drawing of the harness, open a new drawing file, select the command “Front View”, then go to the flattened harness window and select an appropriate face. Right-click the drawing sheet and select properties. In the view tab, select "3D wireframe" and "is always visible" in the dress-up settings to make the bundle segments visible
