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Routed Systems

Presented by:Bassam Najar, Design EngineerButler International Inc.

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Overview

Harness Design Process

Model Associativity

Terminology

Routing without a Diagram Routing with a Diagram

Pro/HARNESS MANUFACTURING

Techniques Documentation

Advantages

Examples

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Harness Design Process

Pro/Diagram

Pro/Cabling Pro/ Harness

Manufacturing

Documentation

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Pro/Diagram

Logical Design

2-D schematic

Captures

connectivity of info

Define Parameters

Wire

Connector

Cable

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Pro/Cabling

3-D Harness Designrouted in assembly

Logical Referencing

captures wire, spooland connector infodefined inPro/Diagram

Logical Data canalso be importedfrom ASCII text files

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Pro/Harness Manufacturing

Automaticallyflattens 3-D harnesscreated in

Pro/Cabling Simulates harness

layout on nailboard

Bends and twists

can be added tooptimize flat harnessshape

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Documentation

Use flat harness indrawing for manufacturingpurposes

Create customized

wirelists and BOM withPro/Report

Use 3-D harness forassembly manuals and

troubleshooting Create and print drawing

at full scale to use directlyon the manufacturingnailboard

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Terminology

Component

An Electromechanical devicethat sends/receives power and/or signals

Connector Connects wires/cables tocomponents or other wires/cables

Node/Pin

Wire or cable attachment point toa 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

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Before Routing

Level of Detail

Connectors shouldyield a useful

footprint in mfg

Connectors shouldhave at least 1 entryport (Csys). The Z-

axis pointing outfrom body ofconnector.

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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

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Routing Without Diagram

Define Harness and Sub-Harness

Designate and Define Connector and

Component ParametersDefine Wire, Cable and Bundle Spools

and Parameters

Define Wire, Cable and Bundle NamesPhysical Routing

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Define Harness and

Sub-Harness

Based on chosen structure, createharness assemblies and assembleusing default component placement

Create harness part within eachharness assembly

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Designate and Define Connector

and Component Parameters

Specify component parametersSpecify entry port(s)

Specify pins callout and signal name

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Define Wire, Cable and BundleSpools and Parameters

A spool is similar to a reel of wire or cable inwhich individual wires or cables are cut. Itdefines the parameters of the wires or cables

(diameter, color, min. bend radius, etc.).Spools must be designated in a cableassembly before routing can begin.

A Sheath spool is used to specify sheathingfor bundles. (Shrink, Tape, Tube Sheath, etc.)

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Define Wire, Cable and BundleNames

Create required wires, cables andbundles

Specify unique name for eachSelect appropriate spool for each

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Physical Routing Options

Entry Port

Cable

Pt/Vtx/Csys

Free

Dependent

Use Dir

Offset

Along Axis

Offset Axis

Location

Follow Cable

AutoRoute

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Routing With a Diagram

Advantages of Logical References

Allows wire list and connectivity info todrive harness (route to the correct places)

Easily track progress

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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 (automaticallycreates 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)

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Pro/HARNESS MFG Techniques

(cont.)

Flattening Process

Set Start PointChoose Auto Fan

Specify Bend Radius within range given

Assemble all componentsModify flattened model as desired (twist,

bend, break, reorient component, etc.)

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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 FutureUse

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Documentation (cont.)

Views Place Mfg Flattened Assemblyand 3-D Harness Model Views asneeded

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Advantages of Pro/E

Provides an image of the physical routing andthe path of each wire and cable, preventinginterference.

Able to determine accurate wire lengthswithout a prototype build, improving time tomarket.

Use 3-D models in assembly manuals

Drawing can be created as full scale andused directly on form board

Logical Referencing saves time by eliminatingduplicate data entry

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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 betweenPro/CABLING and Pro/HARNESS

MANUFACTURING Changes in Pro/CABLING and Pro/HARNESS

MANUFACTURING will be reflected in drawing

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Associativity

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Examples

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Generator Controls

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