Krishna Nadimetla UGS - NASA

Collaborative Wire Harness Design in PLM Environment Krishna Nadimetla UGS 1 UGS Corp. 2007. All rights reserved.

Agenda „ Mechatronics overview „ Wire Harness Design Challenges „ Collaborative Framework „ Use cases 2 UGS Corp. 2007. All rights reserved.

Mechatronics Definition „A mechatronics system is the synergistic integration of mechanical, electrical, electronics and embedded software technologies into electro mechanical products. Mechanical Electronics Mechatronics Electrical Embedded Software 3 UGS Corp. 2007. All rights reserved.

Some Facts „ „ „ Rapidly Increasing Functionality „ Increased package and PCB density „ 80 90% of new functions are electronics based1 „ Rapidly changing technology „ Increased on board diagnostics „ Software based functionality Growing Networks „ Hundreds of kilometers of wires in an aircraft „ Complex interconnections Tighter Physical Constraints „ Smaller enclosures „ Increased number of components „ Electromagnetic interference „ Non planar, flexible circuitry UGS Corp. 2007. All rights reserved. Sources: 1Steiner & Schmidt 2Hoffman & Turner 3Romeo & Marelli 4

Mechatronics Design Environment Mechanical Engineer Marketing Design Data Wire Harness Engineer Specs Design Data Layout Designer Design Data Design Data Manufacturing and Demand Data Architecture Architecture and Specs System Architect Component Supplier Design Data Design Data PCB Engineer Parts Distributor Architecture Design Data Manufacturing Data Manufacturing and Demand Data Design Data Design Data Software Engineer Manufacturing Data Design Data RTOS Supplier PCB Analysis Engineer ASIC Engineer Contract Assembler 5 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 6 UGS Corp. 2007. All rights reserved.

Objective „ Mechatronics overview „ Wire Harness Design Challenges „ Framework „ Use cases 7 UGS Corp. 2007. All rights reserved.

Wire Harness design focus Mechanical Engineer Marketing Design Data Wire Harness Engineer Specs Design Data Layout Designer Design Data Design Data Manufacturing and Demand Data Architecture Architecture and Specs System Architect Component Supplier Design Data Design Data PCB Engineer Parts Distributor Architecture Design Data Manufacturing Data Manufacturing and Demand Data Design Data Design Data Software Engineer Manufacturing Data Design Data RTOS Supplier PCB Analysis Engineer ASIC Engineer Contract Assembler 8 UGS Corp. 2007. All rights reserved.

Challenges associated with Wire Harness Design Process „ Developers designed and located each sub assembly 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 UGS Corp. 2007. All rights reserved. 9

Evolution of Wire Harness Design „ Some of the challenges are addressed by integrating ECAD system with Mechanical 3 D modeling system „ Precise Routing PLM XML RouteList / NX4 „ Exact length of Cable & Bundle data Mechatronics PLM XML / NX4 „ Interference checks „ Design Rule Validation File based: 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 10 UGS Corp. 2007. All rights reserved.

Vision of Harness Design Teamcenter 11 UGS Corp. 2007. All rights reserved.

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 12 UGS Corp. 2007. All rights reserved.

Objective „ Mechatronics overview „ Wire Harness challenges „ Collaborative Framework „ Use cases 13 UGS Corp. 2007. All rights reserved.

UGS Mechatronics Framework 1 2 Mecha Req. Mecha Sys. Eng. 3 Source Code Lifecycle Supported Standards STEP AP 214 STEP AP 210 STEP AP 212 STEP AP 233 PLM XML JT Core Capabilities Security Change Management Configuration Management Data Distribution Workflow Collaboration 4 ESM Binary Lifecycle 5 PCB Lifecycle 6 7 Wire Mecha. Harness Simulation Lifecycle 8 Elc. Mfg. 9 Service & Diag. Mechatronics Data Model Teamcenter Platform 14 UGS Corp. 2007. All rights reserved.

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 15 UGS Corp. 2007. All rights reserved.

Wire Harness Data Model contd „Goal is to integrate the design environment so data can be shared seamlessly between different application environments 16 UGS Corp. 2007. All rights reserved.

Integration Architecture Logical, Routing & Mechanical Design Data NX Manager: PLM XML / Tc2005 – NX4 Logical & System Design Data AIWS: PLM XML / Tc2005 17 UGS Corp. 2007. All rights reserved.

Objective „ Mechatronics overview „ Wire Harness challenges „ Framework „ Use cases 18 UGS Corp. 2007. All rights reserved.

Electrical Design Project Authored in ECAD Tools ECAD Export Publish to Asynchronous Teamcenter Webservice Client 2 Teamcenter Asynchronous Web Service Client Exports or 4 Imports TCe BOMView Data Capital Bridges Teamcenter Application Interface Web Service Client 3 Create AI Object Create Synch Request 8 Import Transfer Mode ECAD TCe Bridges Import Updates wire and Component Properties from Enterprise Integration Export Transfer Mode 5 Electrical Design and Harness Component Level BOMView (connectivity) populated by ECAD AI Web Service ECAD Applications Teamcenter Resource Data Product Data Teamcenter Product Lifecycle Backbone Enterprise Design and Manufacturing Data Context Data Publish Harness Model to Teamcenter Teamcenter NX / MCAD / Enterprise Applications 7 1 NX4/MCAD creates 3D harness models 6 Update Harness Model UGS NX4 Routes 3D Wiring and Exports Mechanical BOM Structure to TCe Updating Electrical View eg Wire Attributes (lengths etc) Use Case – Wiring Design and Release Electrical BOM view in Teamcenter as Populated by NX4 Includes Harness Physical Topology Data

Summary „ Better Integration between 2 D schematic and 3 D 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 20 UGS Corp. 2007. All rights reserved.

Thank you www.ugs.com 21 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