Project 1
Electrical wiring Harness-V16 Engine
Aim:
To route the wiring harness on given engine and prepare flattened view drawing in CATIA V5. Application of all Packaging rules, Industry best practices shall be demonstrated in design. Protection layer for wires is also applied.
Introduction:
Wiring harness is very important for any vehicle. A modern vehicle is connected to different sensors for its safety and performance optimization. Parking sensors, air bag unit, cabin and engine temperature sensors, ABS, electronic stability sensors etc. are required to monitor the vehicle. All the sensors are connected to Engine Control Unit (ECU) with the help of wires. ECU is the brain of a vehicle. Wires are connected to sensors through connectors. A male connector is connected to female connector or vice versa. Connectors are simple and easy to repair in case of any malfunction.
The image given below mention few sensors and control unit.
TE Connectivity is globally known for its electric devices and connectors. In this project all the connectors 3D data is downloaded from www.te.com.
Procedure:
- Given engine (STP) file is imported to Catia V5.
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All the connectors are defined electrically in electrical part design workbench. Supporting devices are also defined.
2P Plug type connector
2P AMP Connector
4P Connector
12P Connector
P clamp
Support equipment
- A catalogue is created, with all the connectors and support equipment which can be used further.
- All the electrically defined connectors are imported into new product file along with the engine 3D data.
- Connectors are placed at the required locations using manipulation and smart snap tools in assembly workbench as shown in the figure.
- Multi-Branches are created connecting all the connectors in wiring harness assembly workbench. Branch radius is varied for different connectors. Bending radius ratio is given as 1.4. Slack is provided when it is needed.
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Protection layer for wires is also provided through corrugated tubes (COT) as shown in figure. 10mm clearance is provided for taping the tubes.
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File is saved using save management to proceed further.
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A new product file is created in wiring harness flattening workbench. Properties are defined as required. All the connector data along with the branches and protective coverings are imported into flattening workbench using extract command.
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Using flatten command, all the branches are flattened along with connector 3D data.
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A new drawing file is created, the flattened connectors are projected into drawing workbench, scale is 1:2. Each connector is color coded, to identify different types of connectors and supporting devices. Protective layer is shown with double line where branches are shown in single line. Number of connectors and their names are mentioned in the given table in the drawing file. A title box is also added below the sheet.
Conclusion:
As mentioned in the aim of the project, wiring harness is completed for the given engine. All the connectors are defined electrically. Connectors are placed and wiring harness is created for the assembly. Protection layer is also provided to the harness. All the connector data is extracted and flattened. The flattened data is projected onto drawing sheet, to provide drafting.
Project files:
All the files are compressed to a zip file. Click on the link below to download all the files: https://drive.google.com/file/d/1zbBglr_Wm4h6BnEOic_8BvxpX1TcojKF/view?usp=drive_link