Project 1

Aim: Route the wiring harness for the Bugatti V16 Engine assembly and prepare flatten-view drawing in CATIA V5.

Objective: The objective of this project is route the wiring harness and proceed with the flatten-view drawing for the Bugatti V16 engine. All types of packaging rules and constraints have to be considered while routing the harness, you must include the  best practices required for packaging and implement in the harness design. All necessary details like clearance/ clamping selection, harness fixing requirements, harness continuity should be provided in order to design the wiring harness.

Inputs Given.

1. CAD file of Bugatti V16 engine
2. CAD data for all the sensors required for routing of the harness.
3. CAD data for the clips and clamps for mounting purpose.
4. CAD data of COT tubes for asthetics and protection purpose.

 Key aspects for the packaging and routing:

1. The most important consideration prior to any step is to thouroughly observe the design for which routing needs to be done, we must be aware of the basic input like types of connectors used for routing, the usage of the clamps etc.
2. The placing of the connectors need to be very precise as, this decides the routing length and even extreme level the routing can be done without fouling.
3. The routing must be done by maintaining the safe distance from the heated compartment like exhaust pipe and engine cylinder (150mm-200mm in general).
4. As engine is bigger compartment, make sure proper clamping and fixing of the bundles in done, so that the bundle is not intercepted by any dynamic component while vehicle is in motion or engine has started its action.
5. Dont give fuel lines as direct support for the routing purpose.
6. In case of complex arrangement , make sure to confirm the use of guiding channel, so that it eschew the complexity of the routing.
7. The excess use of brackets must be avoided on to the engine, try to utilize the threaded boses.
8. The branch length should always be maintained greater than 50mm throughout the routhing bundle.
9. The sack of minimum 5-10 percentage can be provided .

Routing parameters provided:

Here we are provided with the engine assembly and the ports for various sensor is also transcribed in the design, here we have 16 fuel injector sensor , 4 cam shaft sensors , a temperature sensor , transmission sensor and one variable sensor, we have used 4 pole connector for the 16 fuel injectors and 4 cam shaft sensor.For the rest we have used the  pole connector.

The plastic guiding channel used in this harness should be made of a material that can stand at least 150 degrees Celcius.The bend ratio for all the bundle segments is considered to be 1.4 and the P-Clamp suitable for at least 20mm diameter wire is to be used for this project.

STEPS FOLLOWED FOR THE ROUTING.

1)STEP1: CONTEXT ASSEMBLY

Firstly create the context assembly in assembly workbench and then add two products in it, one is the 16V engine for routing purpose and other one is the geometrical bundle assembly for adding the components and creating the multibranchable, and define the geomertical bundle assembly as multibranchable in the electrical harness assembly.

2)STEP2 : ADDING COMPONENTS INTO GEOMETRIC BUNDLE ASSEMBLY

Now start adding the connectors into the geometrical bundle product file but prior to this make sure connector is electrically defined :define the sensor electrically ,i.e the 4 pole connector for the placing of next to the fuel injectors, this can be done with the help of part and electrical part workbench.The 4-pole connector used for this harness assembly is "C-156389-1". The 3D CAD data for this connector was downloaded from TE.com. To define the connector electrically we should define the geometrical parameters, bundle-connection point, and the connector-connection point for the downloaded connector.

3)STEP 3 : FOUR POLE CONNECTOR

Position the 4-pole connector at the fuel injector place and cam shaft shaft sensor place you can simply make use of the manipulation toolbar, compass , snap , and smart move tool in the assembly workbench.

similarly place the sensors for both side fuel injector sensors and cam shaft sensors.

4)STEP 4- TWO-POLE CONNECTOR

The next step is to place the other 2-pole connector on to the temperature , transmission and variable sensor, firstly you need to define the connector electrically by defining it as a connector with two terminals and later defining its connector connection point and bundle entry point .

5)STEP 5- INTERCONNECTION CONNECTOR

The next step is to assign the position for the inter-connection connector, this connector takes in the input of the various connectors with its 12 poles and lends the output to the ECU that takes the respective responses.In our design we will consider that input from the chassis harness comes from the right side so it will be easy for us to connect it with inter-connection connector rather it will also reduce the length of the bundle because placing the connector on left side will ultimately extend the path followed by the chassis vehcile harness.

6)STEP 6: MOUNTING BRACKET

The bracket for the placing on interconnection connector with the moutiong hole is required in order to mount the inter-connection connector rigidly, the bracket will have the clockwise rotation for locking and even the already utilised transimission bolt can be used for mounting purpose of the bracket.It has to be made sure that in the real-world application if we are using any existing bolts or screws then the design idea has to be discussed and passed by the engine design engineering team in order to make sure the proper functioning of the engine. The ribs wil definately support the bracket from fouling.

7)STEP 7: P- CLAMPS

Now you need to place the clamps in order to connect the bundle without fouling, the placing needs to be done at that position where there is provision for clamping of the P-Clamps, these clamps over here will connect our main bundle from the inter-connection conector which will later branched to get connected with the rest of the connectors.The P-Clamps need to de defined electrically as mounting equipment where it can serve purpose for  enrty points and 2 exit points.We have used three P-Clamps over here in our routing mechanism.

8)STEP8: GUIDING CHANNEL

The guiding channel needs to be used for both side fuel injector sensors in order to deminish the complexity of the routing while wiring harness design.To mount the plastic guiding channels we would need some mounting provisions. The engine design team can be consulted and asked to provide mounting threaded holes or threaded bosses. There will be two different plastic guiding channels for this engine. One for the left and the other for the right side of the engine. It has to be made sure that proper clearance (at least 50 mm) is provided between the plastic channel and the exhaust pipes. The total thickness of the these channels is 25 mm.The plastic guiding channel will be a two-piece molded plastic that will protect the wiring harness from surrounding high temperatures, wear and tear while providing nice aesthetics to the engine.

Engine view with all the components which includes 23 total connectors,  2 guiding channels , 1 interconnection connector, 3 P-Clamps, 2 fir-tree clips .

STEP 9: ROUTING FROM THE INTERCONNECTION CONNECTOR.

We start our routing from the interconnection connector with bend radius ratio as 1.4 and bundle diameter as 10mm, and adding sack where it is required .

The main bundle of our routing connects the interconnection connector ,3 clamps and one variable connector .

After that add the fir-tree clip or connecting the branch from the main branch towards the guiding channel and this can be done by introducing the branch point in the main bundle and later defining the routing from from branch point to the fir-tree clip.

Now, create the bundle towards the guiding channel from fir-tree clip and make sure bundle does not foul with the engine body and later using the external cure as measure create the bundle across the guiding channel .

Create the individual branches for routing the branches through the channel towrads the fuel injector connectors, make sure to provide the proper sack, to ensure entry of the bundle through channel without fouling the channel entry.

Similarly create the branching point and connect the sub-branch to the other temperature sensors etc, which are not connected with main branch and also repeat the same thing for routing through the guiding channel on the other side of the engine. Make sure you dont use excess of bundle length for entry into the channel.

STEP 10- PROVIDING THE COT TUBES.

We need to add the cot tubes from our catalog by using the protective covering toolbar in electrical wiring harness assembly , or you can create the new cot tubes into the electrical part workbench. The defined cot tubes over here have given different colour codes.

YELLOW -MAIN BRANCH.

BROWN- SUB- BRANCH CONNECTING THE FUEL INJECTOR CONNECTORS

ORANGE- OTHER SENSORS.

As guiding channel is sufficient for protecting the wire inside so, i have not provided the covering inside the sub-channels.

STEP 10-CHECKING BUNDLE CONNECTIVITY

Now we need to check the connetivity of our bundle and this can be done by using the edit-search-advance-electrical-bunddle segment-fully connected, make a search for the all connectivity to be true.

STEP 11- FLATTENING AND DRAWING

To make a flattened view of any wiring harness we should be working in the Electrical Harness Flattening workbench of CATIA V5. We should also make sure that the flattening file is saved in the same folder where we have all the parts of the harness assembly.

Now set the flattening parameters without which you wont be able to use any flattening workbench toolbar.

By using the extract toolbar add the geometrical bundle inside the flattening assembly.

Now use the flattening tool and also select the guiding channel face as your flattening face and then select the amin guide and click select all branch and then produc twill get flattened.

Use the rotate, blend , and tools to get the desired orientation.

lastly you can go to the drafting workbench and selecting the same guiding channel face as front vie plane add the flattend view in drawing , and set the 3D wireframe as always visible in order to get the differentiation between the cots and bundles and even to get your bundles represented in the drawing .

CONCLUSION:

Routing of the bugatti 16V engnine is done precisely , all industry standards and packaging rules are implemented while routing , flattening and drafting of the harness.