Project 1

Project 1. ( Engine Wiring Harness Assembly Context).

Aim:

Route the Wiring harness on 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 Protection coverings as required.

Objective:

The objective of the project is to route the wiring harness on given V16 Engine and prepare flatten view drawing in CATIA V5. All types of packaging rules have to be considered while routing the harness. Also, Industry best practices should be demonstrated in design. All the necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design wiring harness.

Methodology for define the Connector, Fir Tree, P Clamp, Mounting Clip & Guiding Channel.

Connector Definition -

1. First imported models from given link. open mechanical part design.
2. Defined the middle point with help of the mid point. On the connector side and bundle side.
3. Given axis system to connector side.
4. Now changing the workbench electrical part design.
5. Defined as a connector with required terminations.
6. Then Defined the connector side as the connector connection point.
7. Defined bundle connection side as a bundle connection point.

C-173090-2 (2 Terminal).

C-282080-1 (2 Terminal male)

C-776438-4 (12 Terminal Female)

C-1563689-1 (4 Terminal)

Clip/Clamp & Fir Tree Definition -

1. Get the clip 3D part.
2. Define the Geometry Parameters.
3. Define part as support.
4. Define the entry point & plane.
5. Define the exit part & plane.

P Clamp

Fir Tree

Mounting Clip Definition -

1. define the mounting clip electrically by defining all the properties.
2. Define the clip as mounting equipment using mounting equipment command.
3. Select cavity command and define the parameters.

Guiding Channel Definition -

1. First create geometrical parameters such as bundle entry points, and external reference line in the part design workbench.
2. To route the wiring harness into the guiding channel then define the guiding channel as a electrical part by using the define equipment option.
3. define all the properties to the channel.

Creating Context Assembly

• A Context Assembly for Engine Harness has created which will work as the main assembly as shown in above figure.
• A Context Assembly will contain Engine Assembly data for V16 Engine and Engine Harness Geometrical Bundle Assembly.
• If any sheet metal bracket will require then they are added in the context assembly.
• Here, according to the requirement we are using 'C-1563689' which is a 4-pole connector. This CAD data is downloaded from te.com.
• Adding connectors to the all 16 fuel injector sensors and 4 cam-shaft sensors.
• In this step, we are placing connectors to fuel injector sensors and cam-shaft sensors. So we will require total 20 connectors which have to be added in the Engine Harness Geometrical Bundle Assembly. We have to use manipulation tools along with compass, snap and smart move features to locate all the 20 connectors at their desired locations.
• Adding sheet metal bracket.Now, we have to add sheet metal bracket in order to provide mounting for the interconnection connector.
• Also, we have to make sure that the bracket is placed inside the context assembly and outside of engine and geometrical bundle assembly. The bracket should be mounted on the existing bolt as shown below.
• This bracket should have locking system in clockwise direction so that it can't be move freely. Herein below figure, rib is performing the locking feature for the bracket. All the design ideas should be discussed with the engine designing team so that there won't be any disturbance for the smooth working of engine in real world application.
• Mounting of a plastic guiding channel We have to add now plastic guiding channel because V16 engine has 8 injectors on right side and 8 injectors on left side which are very close to each other.
• Hence plastic guiding channel is best option for proper and easy routing of the wiring harness. It will reduce the complex wiring harness routing. We will require two different guiding channel for both right and left side of the engine. Now, before placing guiding channel, we have to define geometrical parameters of guiding channel as below.

IMAGES OF THE ELECTRICAL HARNESS:

The connectors in the assembly should be electrically defined and it is placed in the appropriated position on the engine surface.After positioning the connectors place the supporting mounting clips in the engine to acheive the proper routing without fouling of the bundle with the surrounding parts.After achieving ths route the harness in the geometric bundle , make sure the bundle segment do not clash with the surronding parts.Flatten the geometric bundle after finalised the geometric bundle , make sure for the bundle connectivity in the wiring harness.

• Adding protective coverings and guiding channels top shell to harness bundle.
• Here in below figure, we have done with whole wiring harness routing for the V16 Engine. Now, we have to add protective coverings to all bundle segments and top shell of the guiding channel.

• Checking bundle continuityIn this step, first we have to make sure that multi-branchable is selected then we have to go in Edit>Search>Advanced>Workbench-Electrical>Type-Bundle Segment>Attribute-Fully Connected.
• By selecting 'True' option will show all the connected bundle segments while selecting 'False' option will show all the non-connected bundle segments.
• Here, we have selected for the 'True' option and searched for results. All the bundle segments are highlighted found showing that all the bundle segments are electrically connected as shown in below figure.

• Creating flatten view of the engine harness geometrical bundle assembly.
• In this step, for creating flatten view we have to work in Electrical Harness Flattening workbench of Catia V5. We should also make sure that the flattening file is saved in the same folder where other files of harness assembly are saved.
• Before creating flatten view, first we have to define flattening parameters. Make sure that selecting 'Single line' for bundle segment and 'Double' line for protective covering.
• We have extracted the bundle assembly into Engine Harness Flattening Product file and then flattened the file along face of interconnection connector as shown in above figure.
• At this stage, for clarity, we have been hidden the flattening diagram of the plastic guiding channels from the drawing view.

We are creating new drawing file and defined all the necessary drawing parameters. We have to insert the front view of the Engine Harness Flattening Product file into the Drawing file.

Conclusion:

• In this way, we have routed wiring harness for the V16 Engine. Also, prepared flatten view drawing with proper sheet in CATIA V5.