Routed Systems

1. Routed Systems Presented by:Bassam Najar, Design Engineer Butler International Inc.

2. Overview • Harness Design Process • Model Associativity • Terminology • Routing without a Diagram • Routing with a Diagram • Pro/HARNESS MANUFACTURING Techniques • Documentation • Advantages • Examples

3. Harness Design Process • Pro/Diagram • Pro/Cabling • Pro/ Harness Manufacturing • Documentation

4. Pro/Diagram • Logical Design • 2-D schematic • Captures connectivity of info • Define Parameters • Wire • Connector • Cable

6. Pro/Cabling • 3-D Harness Design routed in assembly • Logical Referencing captures wire, spool and connector info defined in Pro/Diagram • Logical Data can also be imported from ASCII text files

7. Pro/Harness Manufacturing • Automatically flattens 3-D harness created in Pro/Cabling • Simulates harness layout on nailboard • Bends and twists can be added to optimize flat harness shape

8. Documentation • Use flat harness in drawing for manufacturing purposes • Create customized wirelists and BOM with Pro/Report • Use 3-D harness for assembly manuals and troubleshooting • Create and print drawing at full scale to use directly on the manufacturing nailboard

9. Terminology • Component – An Electromechanical device that sends/receives power and/or signals • Connector – Connects wires/cables to components or other wires/cables • Node/Pin – Wire or cable attachment point to a connector • Spool – similar to a reel of wire, cable, etc. • Wire – A single sheathed conductor • Cable – Two or more conductors contained in the same Jacket • Bundle – Group of cables, wires or other bundles that are sheathed together

10. Before Routing • Level of Detail • Connectors should yield a useful footprint in mfg • Connectors should have at least 1 entry port (Csys). The Z-axis pointing out from body of connector.

11. Before Routing (cont.) • Simplifying Top-Level Assembly • Data Sharing • Copy / Publish Geometry • Shrinkwrap • Skeleton Models • Assembly Structure • Electrical Subassemblies • Electrical Components at Top-Level • Electrical Subassemblies at Top-Level • Sub-Harnesses

12. Routing Without Diagram • Define Harness and Sub-Harness • Designate and Define Connector and Component Parameters • Define Wire, Cable and Bundle Spools and Parameters • Define Wire, Cable and Bundle Names • Physical Routing

13. Define Harness and Sub-Harness • Based on chosen structure, create harness assemblies and assemble using default component placement • Create harness part within each harness assembly

14. Designate and Define Connector and Component Parameters • Specify component parameters • Specify entry port(s) • Specify pins callout and signal name

16. Define Wire, Cable and Bundle Spools and Parameters • A spool is similar to a reel of wire or cable in which individual wires or cables are cut. It defines the parameters of the wires or cables (diameter, color, min. bend radius, etc.). Spools must be designated in a cable assembly before routing can begin. • A Sheath spool is used to specify sheathing for bundles. (Shrink, Tape, Tube Sheath, etc.)

18. Define Wire, Cable and Bundle Names • Create required wires, cables and bundles • Specify unique name for each • Select appropriate spool for each

19. Entry Port Cable Pt/Vtx/Csys Free Dependent Use Dir Offset Along Axis Offset Axis Location Follow Cable AutoRoute Physical Routing Options

20. Routing With a Diagram • Advantages of Logical References • Allows wire list and connectivity info to drive harness (route to the correct places) • Easily track progress

21. Pro/HARNESS MANUFACTURING Techniques • Allows us to create a flattened (2-D) version of the harness in preparation for manufacturing document • Creating the Harness Manufacturing Model • Create Manufacturing – Harness (automatically creates mr_name.mfg and mr_name.asm files) • Select the design harness to flatten • Select simplified rep., if desired • Enter flat harness name (creates fr_name.asm)

22. Pro/HARNESS MFG Techniques (cont.) • Flattening Process • Set Start Point • Choose Auto Fan • Specify Bend Radius within range given • Assemble all components • Modify flattened model as desired (twist, bend, break, reorient component, etc.)

23. Documentation • Tables • Common Table Types • Wire List • Spool List • BOM • Connector / Pin Out Table • Create Pro/REPORT tables • Define Table • Add Repeat Regions (links system info to table) • Enter Report Parameters • Tweak the table • Save and Retrieve Finalized Tables for Future Use

26. Documentation (cont.) • Views – Place Mfg Flattened Assembly and 3-D Harness Model Views as needed

27. Advantages of Pro/E • Provides an image of the physical routing and the path of each wire and cable, preventing interference. • Able to determine accurate wire lengths without a prototype build, improving time to market. • Use 3-D models in assembly manuals • Drawing can be created as full scale and used directly on form board • Logical Referencing saves time by eliminating duplicate data entry

28. Model Associativity • Parametric Behavior • Geometry, location and references can be changed without losing model definition • Associative Behavior • Two-directional associativity between Pro/DIAGRAM and Pro/CABLING • One-directional associativity between Pro/CABLING and Pro/HARNESS MANUFACTURING • Changes in Pro/CABLING and Pro/HARNESS MANUFACTURING will be reflected in drawing

29. Associativity

30. Examples

31. Generator Controls