Project 1

REPORT ON BUGATTI V16 ENGINE WIRING HARNESS

OBJECTIVE:

• To route the Wiring harness on given Bugatti V16 Engine and Prepare flatten view drawing in CATIA V5.
• Application of all Packaging rules, Industry best practices studied in the course shall be demonstrated in design. Apply Protection coverings as required.
• Prepare & Submit all necessary reports like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity, Assumptions if any along with CATIA 3D data.

DESIGN SOFTWARE USED:

• CATIA V5

BUGATTI V16 ENGINE

• Bugatti Engine with 16 valves is shown in image. It has 8 cylinders on the right side as well as 8 cylinders on the left side.
• Each cylinder has injector on it as well as there are 4 cam-shaft sensors. In this way, total sensors countable are 20 that one have to connect electrically.
• Generally, 4-pole connectors are used for fuel injectors of the engine.
• An interconnection connector which is used for connecting the engine to other parts of the vehicle. Here a 12-pole electrical connector with a mounting clip feature can be used as an interconnection connector.
• The plastic guiding channel used in this harness should have to withstand minimum of 150 degree Celsius.
• All bundle segments should be defined with bend ratio of 1.4

Assumptions required for designing wire harness:

1. To provide clips and clamps as per requirement.
2. Additional clips/clamps should be used to avoid fouling case in wiring harness.
3. Apply additional slack of 5-10% if required.
4. Branch length should be greater than 50mm.
5. Minimum distance between two branch points should be at least 50mm.
6. Minimum distance between clip and branch point should be at least 25mm.
7. Use plastic guiding channels if needed for support.
8. Consider avoiding any routing of harness over bolt and bolted joints to avoid harness puncture.
9. Avoid routing on sharp edges or if it is required, provide protection over the harness bundles.
10. Keep wiring harness away from heat generating components by giving clearance distance.
11. Also, protection covering must be provided according to temperature of surrounding.
12. Avoid direct support for harness on fuel lines routed in the engine.
13. Avoid too many sheet metal brackets on the engine. Instead of them, use available threaded bosses on the engine.
14. The wiring harness should be easy to assemble and easy to access.
15. For dummy connectors, define positions which are practical. Bundle diameters and another parameters can be defined for the wire harness routing.

PROCESS OF DEFINING BUGATTI V16 ENGINE HARNESS:-

(1) Creation of Context Assembly :

 

• A Context Assembly for Engine Harness is shown in above figure.
• It contains Engine Assembly data as well as Engine Harness Bundle Assembly for Bugatti V16 Engine.
• If any sheet metal bracket is required then it can be added in the context assembly.

(2) Add sheet metal bracket:

First add sheet metal bracket to provide mounting for the interconnection connector on front side of the engine. The bracket should be mounted on the existing bolt as shown below.

 

(3) Mounting of the interconnection connector on the sheet metal bracket

• a 12 pole connector "C-776438-4" is mounted on cavity clip "C-1924487-2" defined as interconnection connector.
• First, define this 12 pole connector "C-776438-4" as electrically according to figure.

• A mounting clip "C-1924487-2" is electrically defined as shown in figure.

• After electrical definition, 12 pole connector and mounting clip are electrically connected together in Electrical Assembly Design Workbench.
• Now, mount this interconnection connector on sheet metal bracket as shown in above figure.

 

(4) Mounting of the p-clamps as well as Fir tree clip on front side of the engine:

• Here 3 P-clamps needs to be mounted on the existing bolts of the engine.
• But first, P-clamp should be defined as electrically with geometrical parameters such as entry and exit point as well as base plane on it.

• Here, we have mounted 3 P-clamps on the existing bolts of the engine for the wire harness routing as shown in above figure.
• Fir tree clip is required for the smooth routing path to wiring harness towards guiding channel on right and left side of context assembly.

 

(5) Define 4-Pole Connector As Electrical Connector :

• Here, input 4-poles connector used ' C-1563689-1' is provided.

• Go to Electrical Part Design workbench for this given connector. Define it as Electrical Connector.
• Define the Connector Connection Point for it as shown in figure.
• Define the Bundle Connection Point for it as shown in figure.

(6) Adding 20 connectors to proper position on Context Assembly:

• In this step, place all 20 connectors at their desired locations on the Context Assembly by using manipulation tools along with snap and smart move features.

(7) Mounting of a plastic guiding channel:

Here plastic guiding channel is used for making the complex wiring harness routing with easy pathway. Two different guiding channels for right and left side of the engine are needed. But first, define plastic channel as electrical one by selecting ‘Mounting Equipment’.

• As shown in figure, create a point 1 at entry face and another point at endpoint at 550mm distance.
• Now, join that both points and create a line which can be used for routing the wire harness bundle for these guiding channels.
• Use symmetry option to create a symmetrical channel from original.

• Here create bundle entry points for the eight connectors and one bundle entry point at channel entry face.
• Now place the guiding channels at desired locations on context assembly as shown in figure by using different commands like manipulation, snap, smart move, compass etc.

(8) Start bundle routing from Interconnection connector:

• Here start bundle routing from Interconnection connector that goes through 3 P-clamps on context assembly.
• The diameter for this bundle routing is 12mm and bend radius ratio is assumed to be 1.4

(9) Adding branch points to 4 cam-shaft sensors:

• Add branch point to the bundle segment at distance of 60 mm from P-clamp as shown in figure.
• Here two branches are added from the created branch point to cam-shaft sensors. Bundle diameter used here is 8 mm.

(10) Adding branch points to 3 sensors:

• Add branch point to the bundle segment at ratio of 0.5 from P-clamp as shown in below figure.

• Here two branches are added from the created branch point to sensors. Bundle diameter used here is 10 mm.
• Also a single branch is created to left side of engine as shown in image.

(11) Routing towards the plastic guiding channel:

• Another branch point is added from the interconnection connector at distance of 30mm.
• Bundle diameter used here is 10 mm & 8 mm respectively.
• From this branch point, the bundle is routed to the right guiding channel.
• Here fir tree clip is provided in between branch point and guiding channel for the smooth routing.

 

(12) Creation of Branch points:

• Add branch points to bundle segment of the guiding channel.
• Here, seven branch points created at 64.5 mm distance from closed side of channel as shown in figure.
• Bundle segment is routed from these branch points to the 8 fuel-injector connectors.
• The bundle diameter used here is assumed to be 5 mm.
• In similar way, routing is done for the left side guiding channel.

(12) To add protective coverings:

• As shown in figure, 15mm slit COT tubes on top of the bundle segments are added as a protective covering.
• Assumed start and end extremity for the COT tubes approximately 10 mm.
• 5 mm Slit COT tubes are added on all the bundle segments connecting to the all 20 connectors.
• 8 mm and 10 mm Slit COT tubes are added on respective the bundle segments with same diameters.
• Also, top channel to the both left and right side plastic guiding channels are added.

(13) Checking bundle continuity:

• To check bundle continuity, first Multi-Branchable is selected.
• Now, Go to Edit>Search>Advanced
• Select Workbench as Electrical and Type as Bundle Segment
• Select Attribute as Fully Connected
• Select 'True' option & it will show all the connected bundle segments. As well as select 'False' option & it will show all the non-connected bundle segments.
• Here, 'True' option is selected and searched for results. All the connected bundle segments are highlighted showing them electrically connected.

(14) Creation of Harness Flattening File:

• To create flatten view, first open Electrical Harness Flattening workbench in Catia V5. Save flattening file in the same folder where other files of harness assembly are located.
• Now define flattening parameters. Make sure that selecting 'Single line' for bundle segment and 'Double line’ for protective covering.
• Use ‘EXTRACT’ option to create flatten assembly from the bundle assembly in Engine Harness Flattening file. Use flat face of Plastic guide channel as working plane.
• Use 'ROTATE' feature to rotate 8 connectors on one side to 90° in the flattening workbench.
• Flatten assembly is completed as shown in figure.

(15) Creation of Flattened Drawing File:

• Creating a flatten view drawing for the wiring harness assembly.
• Create a new drawing file and defined all the required drawing parameters.
• Insert the front view of the Engine Harness Flattening Product file here.
• Apply text with leader to all components in this drawing file.
• Here Drawing view of the Engine Harness Flatten view is shown.

 

CONCLUSION:

I have learned about preparing wiring harness routing and flatten drawing view for the Bugatti V16 Engine according to industry guidelines from this Project.