Project 1

 

AIM :

To 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.

INTRODUCTION :

A wire harness, also commonly referred to as a wiring harness, is an exterior sheath used to cover some types of electronic wires. Generally, wiring harnesses are made of thermoplastic or thermoset materials that can help protect the cables from the environment.

OBJECTIVE :

 The objective of the project is to route the wiring harness on given 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.

• The above figure shows the 16 valve Bugatti Engine where 8 cylinders are placed on the right side and 8 cylinders are placed on the left side.
• There are total 16 injectors where 8 injectors are used for 8 cylinders on right side and 8 injectors are used for another 8 cylinders on left side.
• Also there are 4 cam-shaft sensors, so there are total 20 sensors that we have to connected electrically.
• Generally, 4-pole connectors are used for fuel injectors of the engine.
• The engine will also have an interconnection connector which will connect the engine to other parts of the vehicle. We will be using a 12-pole electrical connector with a mounting clip feature as an interconnection connector.
• The plastic guiding channel used in this harness should bemade of a material that can withstand at least 150 degree Celcius.
• The bend ratio for the all bundle segmets should be 1.4

DESIGN METHODOLOGY:

• Download the engine CAD data and required connectors CAD data from the given source.

 

• Download the required Connectors from the source and convert the mechanical connectors electrically by using the electrical part design work bench by following below steps.

• First download the connectors and mounting clip from the given link source.
• Get into the mechanical part workbench to create required geometrical parameters. Create connector connection point and bundle connection point on the required sides of the CAD part.
• Create axis system on the connector connection point such a way that the Y coordinate facing normal to the connector face, X coordinate facing towards the locking mechanism and Z coordinate facing to the top.
• Create cavity connection point for connectors having the cavity for mounting clips

Using the geometrical parameters created,

• Define part as electrical connector.
• Define bundle connection point.
• Define connector connection point.
• Define cavity connection point.

C-1563689-1:

C-776438-4:

C-1924487-2:

Create new product file for inter connection connector and cavity assembly.

 

 

• Download and Define the plastic channel electrically

• Procedure for electrically defining the Channel.
• Create bundle entry point and exit point.
• Create a line curve between the main entry and exit points for creating the multi-branchable using external curve inside the channel
• Create 8 bundle entry points on the openings for connecting the injector connectors.
• Using the geometrical parameters, define the channel electrical using the define mounting equipment option.
• Create define bundle entry points using the define bundle connection point option.

Then create a new product assembly with channel bottom and top part assembly. And Create Channel symmetrical assembly and define the symmetry bottom channel electrically using define mounting equipment option and also create all the required geometrical parameters on it.

 

•  Download and define P-clamp and furr tree clip.

 

Creating the Main Assembly:

Context assembly is nothing but the product file which contains the engine 3D-CAD data and the engine harness geometrical bundle. Here the geometrical bundle product contains all the connectors and other mounting equipments, clips and clamps which are electrically defined for the assembly. Sheet metal L-clamp are added in the main context assembly.The we need to switch into the electrical harness assembly workbench and Geometrical bundle product file should be electrically defined using the Define Geometrical bundle option before adding any parts into it.

The Given V16 engine 3D-CAD model requires a total of 23 connectors to be placed on it and an inter connection connector for the engine wiring harness assy. The connectors used in this engine are as follows

• 8 numbers of connectors are required on the fuel injector sensors on each cylinder head, i.e.; total 16 fuel injector sensor connectors are needed.
• Total 4 numbers of cam-shaft sensor connectors are needed.
• 1 neutral position sensor connector and 1 speed sensor connector on the gear box housing.
• 1 engine coolant temperature sensor placed at the center of engine.

 

 

 

 

 

•  Adding 4 pole connectors to all fuel injector sensors as well as for the camshaft sensors.4 pole connectors should be added in the geometrical bundle using copy paste connector or directly import from the catalog created earlier.Connectors can be added again by copy pasting the 1^st imported connector.Place the connectors on all the fuel injector sensors and cam-shaft sensors using the manipulation tools like move, smart move, snap tool and also using the compass. Adding all the other connectors for sensors like coolant heat sensor, neutral position sensor, speed sensors

 

• Placing the Interconnection connector and L-clamp support

However, situation of interconnection connectors are not similar to device connectors. Interconnection connectors are not parked with any device but should be pared with the help of clips/clamps/sheet metal brackets etc. possible to the packaging conditions.Un parked connectors can create following issues-

• Rattling noise
• Physical damage to connectors
• Uncontrolled harness routing
• Manual errors during assembly because of undefined parking.

Assume the bundle connection from the chassis is coming from right side of the engine and therefore L-clamp is provided on the right side of the engine which provide proper support for the interconnection connector. Here the cavity clip is inserted into the hole provided on the L-clamp.Additional slack should be provided to the chassis bundle connecting to the engine harness interconnection connector to protect the wiring harness from vibrations caused during the vehicle operation.From the above pictures we can clearly see that the L - Clip is mounted to one of the holes provide on the Engine block for the screw and it is rested onto the ribs so that it restricts its rotational movement during tightening of the screw.And also, we can see that the Interconnection Connector have been placed and it is Electrically connected with the cavity provided for it.The L - Clip should be added to the main product as it is not a part of the Geometric bundle or the Wire harness bundle.

 

 

 

• Add P-clamps for proper Routing of the harness bundle

Adding supporting components like p-clamps and firtree clip can help the harness bundle provide proper routing and also help to prevent the harness bundles fouling from unwanted mechanical components.

• P - Clamp and the Fir Tree can be placed at required locations to ensure best possible routing for the harness bundles.
• The p – Clamps can be mounted to the holes provided on the Engine block in which the screws to tighten the Engine block.
• The Fir tree clips are positioned according to the requirement during the wire harness routing.
• After finalization of the routing, we can request the Engine design team to provide the holes for the Fir tree clips as per their location.

 

 

 

Routing the wiring harness to the connectors :

Go to electrical harness assembly workbench and select geometrical bundle command and select the geometrical bundle in the model tree. Then select the multibranchable command to start the bundle routing and go to route definition.

• The bundle routing starts from interconnection connector and then to the P-clamps and to the guiding channels. 
• Addding branching points wherever necessary using add branch point command as shown below.
• Adding branches wherever necessary to connect the various connectors to the main branch as shown below using add branches  command and routing definition into it.
• To route the wiring harness through the guiding channels select external curve and click on the line in the guiding channel.
• Add branching points to the wiring bundle and add branches to to connect the wiring to the connectors at the injectors as shown below.
• Add guiding channel top as shown in the image below.

 

 

 

 

Checking bundle continuity:

In 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.

 

FLATTENING HARNESS:

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.

To convert .Catpat file into product file and save as .igs FILE:

After this process it looks like as

FINAL TREE :

 

CONCLUSION:

In this project i have successfully routed the  wiring harness for the V16 Engine assembly and the flatten-view drawing was prepared in CATIA V5. Various packaging rules and constraints were considered while routing the harness. After finalizing the wire routing, we can request the corresponding Engine design team to provide additional holes for the mounting of Fir tree clips.