Automotive

DAF Cable Carrier

Client and producer:

VoestAlpine Polynorm van Niftrik in cooperation with DAF Trucks N.V.

BPO project:

DAF Truck has introduced the new MX 12.9 liter engine some time ago. The cable carrier for this engine, guiding the cables to the electronic fuel injectors and the guidance of the DAF Engine Break, has been developed by BPO in close cooperation with the manufacturer VoestAlpine Polynorm van Niftrik.

The development of the cable carrier is a good example of state-of-the-art engineering. The limited space and special application demand a very complex geometry. Multiple film hinges are used to keep the assembly as simple as possible. It was necessary to use separate parts in some areas because of mutual tolerances and limited space. Supports that can be assembled separately have been constructed because of this around the camshaft and valve rods. The carrier is placed close to the cylinder heads where oil is continuously flowing through with a temperature of 120°C. Because of this a heat resistant and glass fibre reinforced PA6 plastic has been chosen.

More than once during development simulations of the behaviour of the carrier under loading have been carried out. The cable carrier has been analysed and optimized for a number of different loadcases. Special attention was given to the vibrational behaviour at different temperatures. To determine the best possible injection positions and to prevent problems at the film hinges extensive moldflow analyses have been conducted.

Result:

In the end the product not only provides more than adequate protection of the electronic cables during millions of kilometers but it also serves an important role during assembly and maintenance of different engine parts.