Project 1
AIM:
Design and develop the wiring harness on the given engine and prepare flatten view drawing in catia V5. Application of all packaging rules, Industry best practices studied in this course shall be demonstrated in design. Apply protective covering as required.
DESIGN CRITERIA AND PACKAGING ASSUMPTIONS:
- Wiring harness routing shall provide ease in manufacturing, accessibility, easy removal and easy maintenance of attached equipments and routing harness.
- Wiring harness should be routed in such a way that it is easy to assemble on a vehicle.
- Wiring harness should be kept away from sharp environments like sheet metal brackets, panel edges, corners etc.
- Avoid harness routing and clipping in blind zone of operator during harness during installation.
- Ensure that routing meets the clearance requirements with the different surrounding parts.
- Routing shall provide enough slack for each branch to avoid additional stress on wire and terminal crimping joints but ensure that extra slack does not cause wiring harness foul with surrounding parts and impact desired clearance requirements.
- Enough clamps should be provided to ensure the positive clearance with surrounding and safety of wiring harness.
- Use of plastic guided channels are recommended to meet the clearances in critical areas if it is difficult to achieve by use of clamps.
- Branch length should be minimum 50mm.
- Minimum distance between clip and nearest branching point should be 25mm.
- Minimum distance between two breakouts should be 50mm.
- Limit the no. of branches from single branch point to 4.
- Ensure that harness protection is provided according to surrounding temperature, manufacturabilty and expected reliability.
- The min. bend radius is to be 1.4.
- Consider min 5% slack in the wiring harness if needed.
ENGINE:
CONNECTORS:
P-CLAMP:
FIR TREE CLIP:
ROUING:
