1 © UGS Corp. 2007. All rights reserved. Collaborative Wire Harness Design in PLM Environment Krishna Nadimetla UGS
1 © UGS Corp. 2007. All rights reserved.
Collaborative Wire Harness Design in PLM Environment Krishna Nadimetla UGS
2 © UGS Corp. 2007. All rights reserved.
Agenda
� Mechatronics overview
� Wire Harness Design Challenges
� Collaborative Framework
� Use cases
3 © UGS Corp. 2007. All rights reserved.
Mechatronics Definition
�A mechatronics system is the synergistic integration of mechanical, electrical, electronics and embedded software technologies into electromechanical products.
Mechatronics
Mechanical Electronics
Embedded Software Electrical
4 © UGS Corp. 2007. All rights reserved.
Some Facts…
� Rapidly Increasing Functionality
� Increased package and PCB density
� 8090% of new functions are electronics based 1
� Rapidly changing technology
� Increased onboard diagnostics
� Softwarebased functionality � Growing Networks
� Hundreds of kilometers of wires in an aircraft
� Complex interconnections � Tighter Physical Constraints
� Smaller enclosures
� Increased number of components
� Electromagnetic interference
� Nonplanar, flexible circuitry
Sources: 1 Steiner & Schmidt 2 Hoffman & Turner 3 Romeo & Marelli
5 © UGS Corp. 2007. All rights reserved.
Mechatronics Design Environment
Manufacturing Data
PCB Engineer
Architecture and Specs
Marketing
System Architect
RTOS Supplier
ASIC Engineer
Software Engineer
Wire Harness Engineer
Layout Designer
PCB Analysis Engineer
Mechanical Engineer
Manufacturing Data
Contract Assembler
Parts Distributor
Component Supplier
Specs
Architecture
Design Data
Architecture Design Data
Design Data
Design Data
Design Data
Design Data
Design Data
Design Data
Design Data Design Data
Manufacturing and Demand Data
Manufacturing and Demand Data
6 © UGS Corp. 2007. All rights reserved.
Challenges
�Synchronization of mechanical and electrical design representations
�Lack of system design
�Understanding and fullfilling requirements
�Disciplines use different data management
�Disciplines use different design processes
�Lack of or no smooth flow of data across all phases
Significant Challenge Significant Value
7 © UGS Corp. 2007. All rights reserved.
Objective
� Mechatronics overview
� Wire Harness Design Challenges
� Framework
� Use cases
8 © UGS Corp. 2007. All rights reserved.
Wire Harness design focus…
Manufacturing Data
PCB Engineer
Architecture and Specs
Marketing
System Architect
RTOS Supplier
ASIC Engineer
Software Engineer
Wire Harness Engineer
Layout Designer
PCB Analysis Engineer
Mechanical Engineer
Manufacturing Data
Contract Assembler
Parts Distributor
Component Supplier
Specs
Architecture
Design Data
Architecture Design Data
Design Data
Design Data
Design Data
Design Data
Design Data
Design Data
Design Data Design Data
Manufacturing and Demand Data
Manufacturing and Demand Data
9 © UGS Corp. 2007. All rights reserved.
Challenges associated with Wire Harness Design Process…
� Developers designed and located each subassembly in the system with little consideration of the physical and electrical constraints of cabling
� Determine precise routing and length of cable through trial and error
� Synchronization of mechanical and electrical design data
� Lack of Interoperability between tools
� Disciplines use different data management
� Disciplines use different design processes
� Lack of or no smooth flow of data across all phases
� Lack of Change control
� Lack of support for Option and Variant management of Max complexity wire harness
10 © UGS Corp. 2007. All rights reserved.
Evolution of Wire Harness Design
� Some of the challenges are addressed by integrating ECAD system with Mechanical 3D modeling system
Mechatronics PLM XML / NX4+
File based: NX4,
PLM XML RouteList / NX4
� Lack of integrated workflow resulting
� Duplication of design data
� Modification of data is error prone and time consuming.
� Lack of change control
� Point to point integration between multiple design tools
� Precise Routing
� Exact length of Cable & Bundle data
� Interference checks
� Design Rule Validation
11 © UGS Corp. 2007. All rights reserved.
Vision of Harness Design
Teamcenter
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Teamcenter PLM
�Core Capabilities �Security �Change Management �Configuration Management �Data Distribution �Workflow �Collaboration
�Wire Harness Design �AP212/KBL data model �PLM XML support �ITK, AIWS API support �Integration framework
13 © UGS Corp. 2007. All rights reserved.
Objective
� Mechatronics overview
� Wire Harness challenges
� Collaborative Framework
� Use cases
14 © UGS Corp. 2007. All rights reserved.
Mechatronics Data Model
UGS Mechatronics Framework
Teamcenter Platform
Mecha Req.
1 Mecha Sys. Eng.
2 Source Code
Lifecycle
3 ESM Binary Lifecycle
4
PCB Lifecycle
5 Wire
Harness Lifecycle
6
Mecha. Simulation
7
Elc. Mfg.
8
Service & Diag.
9
Core Capabilities Security Change Management Configuration Management Data Distribution Workflow Collaboration
Supported Standards STEP AP 214 STEP AP 210 STEP AP 212 STEP AP 233 PLM XML JT
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Wire Harness Data Model
�Data model based on Industry standard STEP model – AP212
�Provide objects to support entire design process – �Functions, Connections, Signals, Ports, Routing, Topology etc for Logical Design
� Items, Devices for Physical Design
�Allocations to associate components across different phases of development
�Optionally, support KBL specific data elements general_wire, general_terminal, cavity_plug, cavity_seal
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Wire Harness Data Model contd…
�Goal is to integrate the design environment so data can be shared seamlessly between different application environments
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Integration Architecture
AIWS: PLM XML / Tc2005
NX Manager: PLM XML / Tc2005 – NX4+
Logical, Routing & Mechanical Design Data
Logical & System Design Data
18 © UGS Corp. 2007. All rights reserved.
Objective
� Mechatronics overview
� Wire Harness challenges
� Framework
� Use cases
ECAD TCe Bridges Import Updates wire and
Component Properties from Enterprise Integration
8
3
Electrical BOM view in Teamcenter as Populated by NX4+
Includes Harness Physical Topology Data
NX4/MCAD creates 3D harness models
Teamcenter Asynchronous Web Service Client Exports or Imports TCe BOMView Data
ECAD Applications
Teamcenter Product Lifecycle Backbone Enterprise Design and Manufacturing Data
Resource Data
Resource Data
Context Data
Product Data Product Data
2
Electrical Design Project Authored in
ECAD Tools
AI Web Service
Teamcenter
Teamcenter
NX / MCAD / Enterprise Applications
ECAD Export Publish to Asynchronous Teamcenter Webservice Client
4
1
5
Electrical Design and Harness Component
Level BOMView (connectivity)
populated by ECAD
6 Update Harness Model
UGS NX4+ Routes 3D Wiring and Exports Mechanical BOM Structure to TCe Updating
Electrical View eg Wire Attributes (lengths etc)
7
Create AI Object
Create Synch Request
Capital Bridges Teamcenter Application Interface Web Service Client
Import Transfer Mode
Export Transfer Mode
Use Case – Wiring Design and Release
Publish Harness Model to Teamcenter
20 © UGS Corp. 2007. All rights reserved.
Summary
� Better Integration between 2D schematic and 3D Mechanical systems
� Integration provides the ability to design in context
� Unique master data in Teamcenter shared across all stages of design
� Ability to manage workflow and change control
21 © UGS Corp. 2007. All rights reserved.
Thank you
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