Project 1

AIM:

Route the wiring harness on the given engine and prepare the flattened view drawing in CATIA V5.application of all packaging rules, industry best practice studied in this course shall be demonstrated in design. Apply protection covering as required.

ENGINE HARNESS INTRODUCTION:

An engine wiring harness is a set of wires, connectors, terminals, cables, and many other electrical control systems. This set of organized wire harness is to transmission of power and electrical signal from main source to the different areas to perform their functions in the engine.

Some wiring harness are responsible to control the temperature, position of cams, controlling of fuel injection etc.it manages the key functions around the engine including engine controller, oil controller gate, transmission plug housing, air pipe sensors, pressure sensors, and water temperature sensors.

There are many cables in the wringing wiring harness that works to connect electricity to our vehicle parts. This vehicle parts have many sensors, and they work to ensure that every thing in our vehicle is in working order. Some of these major systems in our car are fuel and transmission. When you get a check engine light, you have the engine wiring harness to tank.

It works by using these cables and a fuse box. They wire the electricity produced by the engine to the various parts and sensors. It is created using high-temperature plastic or rubber because the engine heats up a lot. That could cause the engine wiring harness to melt over time. And while this is a rare occurrence, it does happen.

Think of this part of the vehicle like the brain. Without it, it wouldn’t be possible to get the information your vehicle needs. It’s always working overtime to relay the data your vehicle needs to function correctly. Whenever a sensor goes off, it’s because the engine wiring harness alerted the sensor of the problem.

The exciting thing is that as vehicles get more advanced, the engine wiring harness grows. Some say that new cars have over 100 pounds of wires, so imagine how many things could go wrong with that. In the past, there may not have been many issues. However, as things advance, there are more to go wrong.

Engine Wiring Harness protection

Protecting the wires is crucial to the safety of the vehicle. Wires exposed to high temperatures, erosive chemicals and projectiles will be damaged leading to fires, brake failures and critical malfunctions. To prevent these issues, wires need to be bundled and covered.

install wiring insulation or heat shield sleeve material that can withstand direct contact with high-temperature surfaces and is flameproof. It needs to be a material built specifically for under hood automotive applications and withstand constant temperatures up to 125°C, or 257°F.

There are many options for protecting the wires in a vehicle’s harness. Zip ties securely bundle wire together but offer little protection or insulation. Plastic conduits offer protection from rough surfaces, although they can add weight and are not as flexible as other options. Heat-shrink tubing provides protection from heat, moisture and chemicals. However, the application is time-consuming.

Tape is another option for bundling and protecting wires. Tapes are more flexible and cost-effective than other bundling options because they can be used for protective wrapping, bundling and sealing. With a wide variety of backings and adhesives, tape can offer sound dampening, thermal and electrical insulation and abrasion protection of the same quality of the other methods. Additionally, tapes are more flexible, lighter and easier to apply than tubing or plastic conduit.

DESIGN METHODOLOGY:

Step-1:

first we have to download engine CAD file and the necessary required connectors, clips, clamps and guide channels from the given source.

The given V6 engine cad file like below;

Step-2:

After downloading all required connectors and other parts open it in the Catia v5 in the mechanical work bench, now convert all connectors and mounting equipment’s into the electrical components by following below procedure;

· Open the required file in CATIA v5 mechanical work bench, then create the required geometrical parameters to the connectors and clips like point and axis system.

· Create the point in bundle entry side and connector meeting face, now create the axis system connector meeting side with point representation and select appropriate contact, coincidence and orientation.

· If any connector have mounting hosing, then create the axis there also with all representations and define connector connection point, respective mount clip has to defined into electrical equipment.

Now switched into the electrical part design:

· First define it as electrical connector

· Define the bundle connection point in the bundle entry side by selecting created point.

· Define the connector connection point at connector meeting side.

· Define the cavity connection point if any connector needed to mount the clip on the particular location.

C-282080

C-173090

C-1563689

Inter connection connector assembly

Step-3:

Download the necessary clips and clamps from the given source and define it into electrical components;

· Take the p clamp, Furr-tree, fir tree clip creates the geometrical parameters points and planes at entry and exit side of the clamp.

· Go to the electrical part work bench, click on the support option available and fill the entry point, entry plane, exit point, exit plane and base plane to define it as electrical equipment.

· Also define the mounting clip by defining it as a cavity.

FURR_TREE CLIP

L-CLAMP

P CLAMP

FIR-TREE CLIP

Step-4

Download the plastic guide channel given in the source link and define it into electrical component

In guide channel consists two parts ,one is bottom channel and other one is top channel. Both combined together and formed as a closed channel. Bottom channel provides support to the harness bundle and top channel act as a protective covering from top side.

Bottom guide channel

· Create the geometrical parameters like points at entry of guide channel and end of the channel as a exit point.

· Create the curve between the entry point and exit point to create the multi blanchable by using the external reference.

· Create the bundle entry point at each entry of the bundle passing section in the guide channel, in that way have to create the 8 entry points to the guide channel.

· Now define the guide channel into the electrical equipment by using mounting equipment option in the electrical work bench.

· Define the bundle connection point corresponding to created point on connector bundle entry side.

Top guide channel:

· Similarly download it from the given source and open it in Catia v5.

· Go to the electrical work bench and define it as a electrical equipment by clicking on the equipment definition.

Guide channel assembly:

Ater electrical definition the both top and bottom files take into product file to assemble together.

Step-5:

Engine context harness assembly:

Context assembly means that ,it is a product file consists the engine 3D cad data along with the engine harness geometrical bundle and other data.in engine harness geometrical bundle have the fully defined electrical components like connectors, clip & clamps, guide channels and mounting equipment’s etc.

Engine harness geometrical bundle assembly:

Switched into the assembly work bench, imported the all required connectors in to the product file.

In engine harness required the 16 fuel injector connectors,4 cam shaft sensors,1 speed senspor,1 engine coolant temperature sensor connector etc.

4 pole connector:

· Add the 4 pole connector into geometrical bundle assembly for fuel injection system.

· Arrange the all 8 connectors where the mounting is provided with rotating and adjusting the position of the connectors with respect to the mounting connector.

· Also add and arrange again 8 connectors other side of the engine where the mounting provision given.

· Arrange the remain cam positioning ,coolant temperature ,speed sensor connectors in their respective location by selecting suitable connectors.

L clamp & p clamp and Interconnection connector:

After arranging all connectors need to place L clamp near to the main connector to maintain bundle properly in position to avoid bends and their effects in future.in between the connectors where the gap is more than 200mm have to place the p clamps and Furr tree clips.

Adding supporting components like p-clamps and firtree clip can help the harness bundle provide proper routing and also help to prevent the harness bundles fouling from unwanted mechanical components.

Interconnection connector:

However, situation of interconnection connectors is not similar to device connectors. Interconnection connectors are not parked with any device but should be pared with the help of clips/clamps/sheet metal brackets etc. possible to the packaging conditions.

Assume the bundle connection from the chassis is coming from right side of the engine and therefore L-clamp is provided on the right side of the engine which provide proper support for the interconnection connector. Here the cavity clip is inserted into the hole provided on the L-clamp.

The p clamps and l clamps has to fix to the engine outer frame where the holes provided, place the fir clips and Furr clips required location to ensure the better possible routing for the harness bundle.

Adding guide channels into geometrical bundle:

The electrically defined guide channel product file takes into the geometrical bundle and positioning it properly where the location provided to place the guide channel. Also, it has to make symmetry to get channel other side of the engine.

Harness bundle routing:

After arranging all the connector, clamps, clips, guide channels in the proper places have to start the harness routing process from the inter connection connector as below:

· Switch into the electrical harness assembly work bench

· Define the engine has geometrical bundle

· Go to the multiple blanchable, select the diameter of the bundle. Click on route definition select the inter connection connector and other connector to create bundle between them.

· Similarly create the harness bundle in series from right side connector to the left side coolant temperature sensor.

· Now create the branch points between first connector and p clamp to create the sub bundle to right side temperature sensor and click on branch definition to route the harness between.

· Create the branch point again at a suitable distance on main trunk for fuel injector connectors. Route the harness between the branch point and guide channel entry point, after that create the bundle with external reference provided inside the channel by branch definition.

· That inside bundle have to divide into 8 branch points to route individually to 8 connectors at every 50mm distance.

· Go to branch definition and create the bundle harness to all connectors.

Similarly, create the harness routing other side of the engine as below,

Step-6

Electrical connectivity check

After routing harness procedure electrical connectivity checking is important to all bundle are fully connected or not. For that,

· Go to the edit and click on the search

· Go to advance and select work bench, type and attribute, select fulley connected

· Select option which we want either true of connectivity or false any one.

· Click on search to see the connectivity analysis result.

· Now in our case all the bundles are connected fully.

Protection covering:

After finally Completing the wire Harness Routing by following the Packaging Rules we need to Provide Protection Parts Wherever necessary. In wiring harness protection of bundle is important to protect it from many factors like environmental conditions, physical damages, rubbing forces and also good appearance to outside.

So that have to cover or insulate the bundle with coregulated tube, insulation tapes etc.in our case we applied the cot tubes over the bundle based on the bundle diameter. The cot tubes are taken from the catalogue created earlier.

This process done in the harness assembly work bench ,clicks on the protective cover and select the bundle with suitable cot tubes in the catalogue browser.

Step-7:

Wiring harness flattening:

Wiring harness bundle routing and packaging completed. Now we have to make the geometrical bundle into the flatten wiring in the electrical harness flattening workbench.

For that we have to follow as below;

· go to the electrical harness flattening work bench

· create the new product file and save it with suitable name

· define product into flatten file by click on harness flatten definition and confirmed the related asking conditions in it.

· After that click on the flatten, then the geometrical bundle converted into flatten harness.

Step-8:

Create the drawing of flattened harness product:

· Create the new drawing file and select the drawing parameters

· Click on the front view in the drawing work bench, go to the flatten product and select the surface of any part and click on ok

· Now we get the 2D drawing of the flatten harness design and add related layout and other description of the drawing if need.

Final output:

Conclusion:

in this project successfully completed wiring harness design for the v6 engine assembly,applied protection covering and flatten the engine geometrical bundle and converted the flatten harness into 2D drawing in drawing work bench.

drivelink:

https://drive.google.com/file/d/1m6XYsKXPm7JySrERqgIUBZAgOj54S3EZ/view?usp=sharing