Project 1
Aim- To route the wiring harness of given Engine model and prepare flatten view drawing in CATIA V5.
Objective- Objective of this project is to route the wiring harness and prepare flatten-view drawing for the given V16 engine model and considering all types of packaging rules and constraints while routing the wiring harness.All necessary details like clearance/clamping selection,harness fixing requirements,harness continuity should be provided in order to design the wiring harness.
Above figure shows the given V16 engine model for which wiring harness has to be designed.
Assumptions and design rules considered while designing the wiring harness for the given V16 Engine model.
1.Provide additional slack if needed according to the surrounding and harness bending requirement.Generally slack between 5-10% is sufficient.
2.The minimum distance between two branch points should be atleast 50mm.
3.Use plastic channels if needed.
4.Branch length should be greater than 50mm.
5.Protection should be provided as needed accoprding to the surrounding temperature.
6.Avoid direct support of harness on fuel lines routed in the engine.
7.It should be noted that there is no case of fouling while designing the wiring harness in CAD software.Clips and clamps can be used to avoid fouling.
8.Avoid harness routing near sharp edges.
9.Keep away from heat generation components and follow clearance distance.
10.The wiring harness should be easy to assemble and easy to access.
The given engine model has 16 fuel injector sensors and 4 cam-shaft sensors that is a total opf 20 sensors.We used 4 pole connectors for fuel injector sensors and for cam-shaft sensors also.
The engine will also have an interconnection connector which will connect the engine to other parts of the vehicle.We used 12-pole electrical connector with a mounting clip feature as an interconnection connector.
The plastic guiding channel used in this harness should be made of a material that can withstand atleast 150 deg celcius.
P-clamp of 15mm diameter is used in this project.
CONTENT-
STEP 1- Creating engine harness assembly context.
STEP 2- Defining 4-pole connector electrically.
STEP 3-Adding connectors to all 16 fuel injector sensors and 4 cam-shaft sensors.
STEP 4-Adding sheetmetal bracket for mounting interconnection connector.
A sheet metal has to be created in order to provide mounting for the interconnection connector.We have to keep that in mind that the bracket is placed inside the context assembly but outside the engine and harness geometrical bundle assembly.The brcaket can be mounted on the existing bolt located as shown below.
We assumed diemension for creating the L-shaped bracket,it must be noted that a mounting slot is provided on the L-shaped bracket for the interconnection connector.A slot is provided in order to avoid any rotational motion.
STEP 5-Defining the interconnection connector and mounting clip electrically and then mounting it on the created L-shaped bracket.
A 12-pole "C-776438-4" connector and mounting cavity "C-1924487-2" is used as an interconnection connector.The 3D-CAD data file for the required connector and the mounting cavity is downloaded from TE.com.Both the connector and mounting cavity is defined electrically and mounted in the sheet metal L-shaped bracket.
STEP 6-Mounting of P-clamps.
A P-clamp of 15mm diameter is designed in order to route the wiring harness.
The above figure shows a P-clamp mounted on the existing bolt of the engine.Before mounting we defined the P-clamp electrically.
A total of 3 P-clamps are used for this wiring harness.They all are mounted on the periphery of the engine on the already existing bolts.
STEP 8-Plastic guiding channel.
Given V16 engine model has 8 fuel injectors on the right side and 8 fuel injectors on the left side of the engine.All the fuel injector sensors are located very close to each other.So, the best way to route the wires around them is by using plastic guding channel.To mount the plastic channels we need some mounting provisions.The engine design team can be consulted and asked to provide mounting threaded holes or threaded bosses.
There will be two different plastic guiding channels for the engine,one for the left side of the engine and one for the right side of the engine.The thickness of these channels is kept as 2mm.
Plastic guiding channel is designed by assuming certain dimensions,given below the required dimensions taken while designing the plastic guiding channel.
Above figure shows the upper part of Plastic guiding channel.
Above figure shows both upper and lower part of plastic guiding channel.
STEP 9-Drawing guiding sketch for the plastic guiding channel and defining channel electrically.
Above picture shows that the plastic guiding channel is defined electrically.
STEP 10-Locating the guiding channel
STEP 11-Engine with all mounting and guiding provisions.
Above figure shows all the 20 connectors,2 plastic guiding channels,3 P-Clamps, and an interconnection connector mounted on the sheet-metal bracket.
STEP 12-Bundle routing from interconnection connector to three P-clamps.
STEP 13-Adding branches to 4cam-shaft sensors located near the interconnection connector.
STEP 14-Routing through the guiding channel and routing bundle segments to the left 8 fuel injectors and right 8 fuel injectors.
STEP 15-Applying protective covering.
Above figure shows that the protective covering is applied on the main trunk
Above figure shows that the COTTON tape is used for the connection of fuel injectors.
STEP 16-Checking Bundle continuity.
First,we have to make sure that the multi-branch able is selected and then we have to go in "EDIT>SEARCH>ADVANCED>ELECTRICAL WORKBENCH>TYPE-BUNDLE SEGMENT>ATTRIBUTE-FULLY CONNECTED."
Selecting the "TRUE" option will ahow all the connected bundle segments while selecting "FALSE" will show all the non-connected bundle segements.
In our case we select TRUE and search for results.All the bundle segments are highlighted and found showing that all the bundle segments are electrically connected.
STEP 17-Creating flatten pattern of wiring harness bundle.
To make a flattened view of any wiring harness we should be working in the Electrical Harness Flattening workbench of CATIA V5.We should also make sure that the flattening file is saved in the same folder where we have all the parts of the harness assembly.
Defining the Harness Flattening parameter.Make sure to use the "single line" for the Bundle segment and "Double line" for protrctive covering.
Extract and bring the bundle assembly into the car body flattening product file and then flatten the harness along YZ Plane.
Now we used Roll command for better representation of the wiring harness.It should be noted that we have YZ-Plane as the flattening plane so we should make sure that we roll the bundle segment only along YZ-Plane.
STEP 18-Creating a flatten-drawing view for the wiring harness assembly.
Above figure shows the flatten drawing view for the wiring harness assembly.
Below are the few images of the routing on the given V16 Engine Block.