Project 2

AIM:

To route the wiring harness bundle for the given body.

Objective:

• The main objective of this project is:
• To create the wiring harness routing for the given Car body by using appropriate connectors, clips and clamps which is required.
• To create a flatten view drawing file in Catia v5.
• Need to apply the protection covering like cot tubes and insulation tapes to the bundles as required.
• Need to apply the industry best packaging rules and best practices studied in this course.

Packaging rules and assumptions made in this project:

• Avoid harness routing and clipping in a blind zone.
• Avoid harness routing through the small structural holes and openings to minimise the chaffing and handling of the wiring harness during installation.
• Provide additional slack to the harness according to the surrounding and harness bending requirements. And avoid excess slack to the harness.
• Provide sufficient clearance to the different surrounding parts.
• Avoid routing over the bolts, near to the bolted joints or screwed joints. Because it may damage the harness or may puncture the harness.
• Avoid routing near the sharp edges like thin sheet metal brackets, panel joints, etc.
• Provide at least 100mm clearance to the harness from the ABC pedals, clutch lever & cables, Engine timing belt or any other dynamic components.
• Enough clips and clamps should be provided to ensure the positive clearance with the surrounding and safety of the wiring harness.
• Ensure distance between two clamps on a straight branch should be maximum of 200mm.
• Clamping requirements should be decided based on the harness bending, surrounding and mounting arrangements.
• Provide positive clamping at the engine and chassis to avoid the harness damage when Engine rocks.
• Keep harness away from the transmission dynamic assemblies like drive shaft or propeller shaft.
• Provide the guiding channel if it is required.
• Use the rubber gromets which provide the proper sealing, and also protects the harness from the sharp edges and absorbs the vibrations.
• Wiring harness minimum branch length should be 50mm.
• Minimum distance between the clip and nearest branching point should be atleast 25mm.
• Minimum distance between two breakouts should be 50mm.
• Limit the number of branches coming out from the single branch to 4.
• Provide the bracket for the interconnection connector parking.

Steps followed for creating the wiring harness routing to the given V-16 Engine:

STEP 1: Download the cad files of the given car body, connectors, clips and clamps.

CAR BODY (TAIL GATE ):

Defining all the connectors as electrical components and the clips as the supporting equipment.

ALLIGNING CONNECTORS AND CLIPS TO THE BACK DOOR:

ROUTING THE WIRING HARNESS:

Preparing the flattening view of the wiring harness assembly

DRAWING FILE FOR WIRING HARNESS ASSEMBLY: