Project 1

V16 ENGINE WIRING HARNESS ROUTING IN CATIA V5

AIM ; The aim of the project is to route the wiring harness on given engine and prepare flatten view drawing in catia V5.

OBJECTIVE 

The objective of the projects are first to route the wiring harness in the given v16 engine and then create the flattened view of the routing and create drawing of it.while routing all types of packaging rules should be considered.

INTRODUCTION 

An engine wiring harness is an arrangment of wires cables ,connectors and terminals that controls a vehicle electrical system.The given engine is a v16 engine which consist of following electrical components to which the wiring harness is routed

• The given engine consists of 16 injectors totally for the 16 cylinders assembled in both sides of the engine and for this 16 injectors we  use 4 pole connector for connecting them electrically.
• Here 4 cam shaft sensors are also there, here also we use 4 pole sensor for electrically connecting.
• Engine coolant sensor ,engine oil temperature and pressure sensor fitted at the oil sump of the on both engine cylinder blocks, which are coonected electrically by 2 pole  connectors.
• An interconnection sensor is also used to connect the engine wiring harness th vehicle wiring harness system.

Other equipments required for the routing are the folllowing

• Guiding channels to protect the harness routing from high temperature zones of the engine in this engine routing guiding channels are used in two places
• p- clams are used for the positive clamping and clearnce management for the routing , and also L-clips are used for mounting the interconnector
• corrugated tubes are used for the protection of wirings

DESIGN CRITERIA AND PACKAGING ASSUMPTIONS FOLLOWED IN THE ROUTING

• The wiring harness routing shall provided ease in manufacturing, accesibility , easy removal , and easy maintenance
• Routing through the small structured holes and openings shall be avoided 
• avoid the harness routing and clipping in the bind zones of the operator for the ease of service
• Give proper additional slsck for the harness according to the surroundings and harness bending requirements
• And aslo ensure the routings have proper clearence with the surrounding parts
• avoid routing over the bolts , near to the bolted joints.
• Avoid harness routing near the sharp edges, if it is not possible then give proper protections for it
• Maintain the proper distance between the two clips in a  straight branch , take it as 200mm maximum
• The use of two many sheet metal brackets should be avoided
• Ensure the  branch length should be more than 50 mm
• Min distance between clip and branching point is to be 25 mm.
• minimum distance between two branch point should be 50 mm.

PROCEDURE 

STEP 1 - Creating context assembly

A context assembly is created  which is named as assembly of engine harness context and the all other components comes under context assembly , which is the main assembly . A context assmbly contains assy of v16 engine and engine harness geometrical bundles

STEP 2 - Define all the equipments like connectors, clips ,channels, mounting eqipments required for thr routings electrically using electrical part workbench.

CONNECTORS

Define all the connectors as electrical connector using electrical part workbench and define its bundle connection point and connector connection point as shown below.

• 4 POLE CONNECTOR(C-1563689)

• 2 POLE CONNECTOR

• 12 POLE CONNECTOR(C-776438-4)

P- CLAMP

Define the p-clamp as an electrical support and define its bundle exit and entry point. as shown below.

GUIDING CHANNEL

Define the guiding channel as mounting equipment and then define bundle connection point on the entry phase of the channel and at the eight openigs of the channel to define the channel as an electrical component.

STEP 3 - Arrange the connectors at the respective positions.

• Here 4 pole connectors are placed in the 16 fuel injectors sensor on the two side of the engine and also 4 pole connectors are places in the 4 cam shaft sensor as shown below these connectors are comes under geometrical bundle tree

• Two pole connectors are placed in the Engine coolant sensor ,engine oil temperature and pressure sensor fitted at the oil sump of the engine on both engine cylinder blocks as shown below

• Mounting the interconnection connector on the sheet metal bracket , here a 12 pole connector is used for the interconnection of the engine harness to the vehicle main wiring harness . the interconnection connector are placed in a sheet metal bracket and and it is electrically connected using a mounting cavity to the sheet metal bracket as shown below.

STEP 4 - Adding p-clamps for wiring harness at required positions

• Here we use 3 p-clamps on the engine at respective positions p-clamps are also placed on existing bolts therefore additional effort for p-clamps instalation can be reduced.
•  P- clams are used for the positive clamping and clearnce management for the routing. 

STEP 5 - Mounting of plastic guiding channel at high temperature zones .

• Here guiding channels are used near the fuel injector region of the engines , that is one of the high temperature zone of the engine through the which routing take place.
• Here plastic guiding channels are used since the given v16 engine has 8 fuel injectors on both sides and they are tightly packed , plastic guiding channels are the best way and proper easy way to routing of the wiring harness
• After placing the bottom part of the guiding channel its top part also added to the geometrical bundle and arrange it as per the fig below.
• The guiding channel for one side is only given, by using symmetry tool in the assembly workbench we can create symmetry of the guiding channel to the other side by the respective planes.
• Here we use manipulation , snap , smart move options to arrange the guiding channels properlly.

 STEP 6 - Bundle routing starts from interconnection connector 

• After the arrangement of the all the equipments needed for the routing the bundle routing starts.
• The routing starts from the interconnection connector to the 3 p- clamps arranged as shown in the figure
• The bundle diameter is taken as 15 and bend radius is taken as 1.5 for these bundle segments.

• After that create branching point where ever needed for the connection of the connector placed in camshaft oil sump etc and route bundle segment to these connector from the branch point
• Here the diameter of the bundle is taken as 5 mm and the bend radius of 1.5
• The branch length is maintained above 50 mm for all the connectors
• And also proper slack is given to the bundle segment.

• Next the routing from main branches to the guiding channels starts and later the connectors placed in the fuel injector is connected by creating branching points in the bundle passiong throgh the guiding channels.
• The diameter of the bundle  segment connecting the main branch and the guiding channels are 10 mm and bend radius 1.5 respectively.

STEP 7 -  Adding protective covering to the bundle segment

• After completion of the routing of bundle segment next step is to add protective coverings  here we have used COT tubes for the protective covering of the bundle segment .
• Here COT  tubes of size 20mm , 15mm , and 10 mm are used mainly. 
• And given end extrimity and extrimity to the cot tubes by 15 mm

STEP 8 - Checking bundle continuity

• Bundle continuity is checked to confirm whether the bundles are fully connected or not 
• the bundle continuity is checking as per the images below

• Here we have given TRUE option and searched the result . all the bundle segment are highlighted and from this we can confirm that all the bundles are connectd

STEP 9 -Creating flatten view of the engine harness geometrical bundle

• For this we want to switch to electrical harness flattening workbench
• At first create a new product file and save it in the same folder of engine harness context assembly
• Then add flattening parameters as shown below

• Next step is to extract the geometrical bundle to the flattening product assembly usng extract option.
• Then by selecting a plane we can start flattening by selecting a plane to which we want to flattend ,here we select inside face of the channel as active plane for flattening

• We have created the flatten view of the bundle segment as shown below , here we used various comands for the arrangement of the bundles like rotation roll , etc.

STEP 10 - Creating drawing of the flattened view

• Create a new drawing file 
• Then take the front view of the flattened view using front view options and arrange the drawing in the drawing sheet as shown below

CONCLUTION

In this way we have routed the wiring harness