Routed Systems

Presented by: Bassam Najar, Design EngineerButler International Inc.

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

Harness Design Process

Pro/Diagram Pro/Cabling Pro/ Harness

Manufacturing Documentation

Pro/Diagram Logical Design

2-D schematic Captures

connectivity of info

Define Parameters Wire Connector Cable

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

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

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

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

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.

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

Routing Without DiagramDefine Harness and Sub-HarnessDesignate and Define Connector

and Component ParametersDefine Wire, Cable and Bundle

Spools and ParametersDefine Wire, Cable and Bundle

NamesPhysical Routing

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

Designate and Define Connector and Component Parameters

Specify component parametersSpecify entry port(s)Specify pins callout and signal name

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.)

Define Wire, Cable and Bundle Names

Create required wires, cables and bundles

Specify unique name for eachSelect appropriate spool for each

Physical Routing Options

Entry Port Cable Pt/Vtx/Csys Free Dependent Use Dir

Offset Along Axis Offset Axis Location Follow Cable AutoRoute

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

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)

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.)

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

Documentation (cont.)Views – Place Mfg Flattened Assembly

and 3-D Harness Model Views as needed

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

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

Associativity

Examples

Generator Controls