Project 1

ENGINE WIRING HARNESS USING CATIA V5

Statement of assignment:

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.

Available connector 3D data can be used, or you can download the connectors from www.te.com

Prepare & Submit all necessary reports like clearance, Clipping/Clamping selection, Harness fixing requirements, Harness continuity, Assumptions if any along with CATIA 3D data.

Introduction-

The Bugatti W16 engine is a powerful.The Veyron features an 8.0-litre, quad-turbocharged, W16 cylinder engine, equivalent to two narrow-angle V8 engines bolted together. Each cylinder has four valves for a total of 64, but the configuration of each bank allows two overhead camshafts to drive two banks of cylinders so only four camshafts are needed.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

Aim-

To route the wiring harness on given Engine and flatten view drawing in CATIA V5.

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.All the necessary details like clearance, clipping/clamping selection, harness fixing requirements, harness continuity should be provided in order to design wiring harness.

Rules to be followed-

1. Wiring harness should be routed in such way that it is easy to assemble and access.
2. Easy manufacturing, installation, removal and maintenance have to be considered while designing the wire harness.
3. Wiring Harness should be kept away from sharp environment like edges, corners etc.
4. Avoid harness routing and clipping in the blind zones or hard to reach areas during harness assembly or service.
5. Provide additional slack if needed according to the surrounding and harness bending requirement. If harness is passing through the closures/doors or tail gates then envelope dimensions during opening and closing of doors shall be considered to provide the slack. Check the harness slack requirements with open and close conditions to avoid excess slack.
6. Routing through small structural holes and openings shall be avoided. To minimize chaffing and handling of the wiring harness during installation.
7. It should be make sure that there is no case of fouling while designing the wiring harness in the CAD environment. Additional mounting equipments like clips/clamps may be used to avoid fouling.
8. Use of rubber grommet is recommanded if harness is passing through sheet metal panels. Example- firewall, passing to door, tail gate etc.
9. The branch length should be greater than 50mm.
10. The minimum distance between the clip and branch point should be at least 25mm.
11. The minimum distance between the two branch points should be at least 50mm.
12. Clips/clamps used for the wiring harness should be easily available in the market to avoid extra cost for custom mounting solutions.

Steps required-

STEP 1 - Creating context assembly

Open the Engine assembly in the catia making an assembly product file. 

                                                                Bugatti V16 Engine

STEP 2 - Defining connectors electrically

Choosing right components for the wire harness routing.here we are using the components for electrical equipment.the connectors used are first elecrically defined and then added to the catia model.

The type of connectors used are given below-

1- Interconnection connector

2-Clip and clamp is used to set the location of wire

3-Sheet metal bracket

4-2 pole connector

5- 4 pole connector

5- Bottom channel support

STEP 3 - Adding connectors and needed equipments

Opening the equipments in catia and using the snap and smart move and positioning the connectores and supports.

The first part we position here is the interconnection connectors.

we place the p clamps for the support in the needed positions.

proper connectors are positioned for different electrical equipments

STEP 4 - Bundle routing

The routing starts with interconnection connector placed on the L clip 

it is continusly routed to the following supports

the major routing supports used here are the p clams 

STEP 5 - Bundle continuity check

Now we check the bundle continuity check for the further process.

the continuity checked of TRUE

the continuity checked of FALSE

STEP 6 - Adding protective covering to the harness bundle

By using protection covering tool we protect all the bundle.we have created a catlouge and we add the protection cover of 15mm diameter and 10 mm diameter.here we Create a gap from the end and start extremity.

STEP 7 - Create flatten view

Now we open a new product file for the Electrical harness Flattening.here we save the already made geometrical bundle segment and we extract the geometrical bundle to flatten harness by apply flattening parameters we flattten the geometrical bundle.

once the branches are flattened we do some modification in the branches using the Rotate,bend,straighten etc tools in the Electrical harness flattening.

STEP 8 - Creating a flatten view drawing

After the modification we synchronize the changes wich are done to the real file and then we open new file for drawing using A0 size having scale of 3:4.and we extract the flattened model to the new drawing sheet made.

Final Catia view of engine harness context

ISOMETRIC VIEW

TOP VIEW 

BOTTOM VIEW

SIDE VIEW

FRONT VIEW

BACK VIEW

Conclusion - Routing of the wiring harness for the engine assembly has been succesfully done and prepared flatten-view drawing in Catia V5 as per the design requirements.