Project 1

AIM:

To route the wiring harness on given engine and flatten view drawing in CATIA V5.

OBJECTIVE:

• Route the wiring harness and flatten view drawing of given engine is created using 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.

ENGINE ROUTING PROCESS:

• 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 are total 16 injectors are are placed where the 16 cylinders on the engine.
• There are also 4 cam shaft sensors are placed on engine. So there are total 20 sensors that we have connected electrically. Generally 4-pole connectors are used for fuel injectors and cam shaft 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 connecctor with a mounting clip feature as an interconnection connector.
• The guiding channel used in this harness should be made of a material that can be withstand of minimum 150 degree celcius.

Design Criteria for Wiring Harness:

• Provide clips/clamps as per requirements.
• Strictly follow that there is no fouling is acceptable while during the wiring harness. If necessary to use additional clips/clamps to avoid fouling.
• Avoid routing over bolt and bolted joints to avoid harness puncture. Also avoid routing on near the sharp edges or give the best protection of harness to prevent damaging harness.
• Follow the clearance distance and keep away the harness from heat generated components.
• Avoid direct support for harness on fuel lines routed in the engine.
• Use guiding channel if it is needed.

Packaging rules and Best practices:

• Follow the design consideration for the minimum length of harness branch. Branch length should be greater than 50mm.
• Minimum distance between two branch points should be 50mm.
• Minimum distance between clip and brance point should be 25mm.
• Avoid too many sheet metal brackets on the engine. Try to use available threaded bosses on the engine or demanded it.
• The wiring harness should be easy to assemble and easy to access.
• Give the additional slacks if needed. 5 - 10 percentage of slack is mostly enough.
• 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 wiring harness routing.
• If the packeging 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.
• Keep the harness away engine heat generation components like exhaust manifold, Turbo chargers, EGR component and heating lines.
• Avoid direct support for harness on fuel lines routed in engine.
• Try to avoid use of too many sheet metal brackets on engine. Try to use the available threaded bosses on engine or demand for it.
• Limit the number of branches from single branching point to 4.
• Ensure that harness protection is provided according to surrounding temperature, manufacturability and expected reliability.

ENGINE WIRING HARNESS ROUTING PROCESS:

• In first we want to create the bundle connection point, connector connection point and axis system for all the connectors and guiding channel.
• Next we want to define all connectors and required components electrically. And also we want to define bundle connection point, connector connection point and cavity connection point for the connectors.
• Now we add the connectors to catalogue file.

C-776438-4 (interconnection connector):

C-173090-2 (2-pole Connector):

C-282080-1:

C-1563689-1 (FUEL INJECTION SENSOR):

C-1924487-2:

COOLANT TEMP SENSOR:

CAM SENSOR:

GUIDE CHANNEL:

P CLAMP:

FURR TREE CLIP:

Creating context assembly:

• When completing all connectors and components as electrical component then we create the context assembly for engine harness which will work as the main assembly file.
• Next we create the geometrical bundle assembly on the context assembly file.
• Then add the all connectors and required component. Place the all connectors, mounting parts and support parts for the correct places.
• If any sheet metal bracket will require then we add in the context assembly.

• When completing to create the required assembly files and add sheet metal components to the context assembly then we want to add the 16 fuel injection sensors and 4 cam shaft sensors and placed it to the required position.
• Use manipulation tools, compass, snap and smart feature commands to placing all connector for desired locations.

• Next we add the cam coolant temp sensor and place the correct position.

• Add another required connectors like C-173090-2, C-282080-1 and 2-pole coolant temp sensors and place the desired positions of the connectors.

• Now we want to add the sheet metal bracket to provide mouting for the interconnection connector mounting.
• We placed the sheet metal bracket to inside the context assembly and outside of geometrical bundle assembly. Bracket should be placed to the existing bolt mouting location. This bracket should have locking system in clockwise direction so that is can't be move freely.
• All the design ideas should be discussed to the engine designing team so that there won't be any disturbance for the smooth working of engine when is working.

• Next we add the P-Clamp for the purpose of compatability when creating harness of the engine. So we need 3 P-clamps and place the clamps to the bolt existing holes for avoiding extra holes creation.

• Now we add fir tree clips to avoid the fouling of harness from the engine body or sharp corners of the engine parts. Also it helps to harness branches path way without any collision.

• We want guide channel to avoid the engine heat to affect wire harnesses. Create the required design of guide channel and placed to the desired location and define electrically as mouting part. In this guide channel is helped to connect all 16 injection connectors harness.

• We finally placed all connectors, clamps, clips and guide channel in desired location next we do bundle creation process.
• In first we are routing the bundle segment from interconnaction connector to 3 P-clamps.

• Do the bundle segment creation and connect all connectors with help of clips and guide channel. Create the branch points when required two or more connection in same places. And also keep in mind to branches not exceed 4 in one branch point.
• Also give the slack when it requires.
• Use guide channel for connecting branches to the 16 fuel injection connectors. create the branch point separarely for all indivudual connectors in fuel injection connectors.
• Connect all connectors like coolant temp sensor, cam sensor, and also other 2 connectors also.
• During bundle segment creation any connection is not acceptable when it collide or negative connections.

• When creating bundle segment creation is completed Next we want to check the connections are connected continously.
• First we go to edit option then select search option. Next select advance option for the appeared dialog box and select option like workbench as an electircal, type as bundle segment and attribute as a fully connected.
• In first we check the false option for any connection is not connected properly. Then check true option if wanted.

• We have to add protective coverings to all bundle segments and top shell of guide channel also added.
• We have to add 10mm COT tube covering and 5mm COT tube covering for the bundle segment. Edit starting and end extremity for the connector end and branch point placed positions.
• We want to add the slit type COT tube in guide channel nearest bundle connections for comfortable placing of protective covering.

• In next step we want to creating flatten view of the engine harness geometrical bundle assembly.
• For creating flatten view we have to work in electrical harness flattening workbench.
• Before creating flatten view of engine harness geometrical bundle assembly, we have to define flattening parameters. Make sure that selecting option as we required to defining all connection.

• Next we creating a flatten view drawing for the wiring harness assembly.
• We are creating new drawing file and define all the necessary drawing paramenters. Then use front view command and select the required view as a front view of the drawing and create the drawing of flatten view file.
• Define all connectors for the reason of identificaiton easily. And to the required methods to presenting the drawing of flatten engine harness assembly.

CONCLUSION:

Finally, we completed routing wiring harness of given V16 engine and creating flatten view and flatten view drawing. Also consider the design parameters and packaging rules and industrial best practices.