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Manufacturing Documents

1. EEEEEEEEE MMM MMM DD DD EE HHHH DD DD EEEEEEE MM DD DD EE HH HH DD DD EE MM MM DDDDDDDD HH HH MANUFACTURING REPORT 10 gt COIL SUMMARY A Manufacturing Report Danner Page Each banner page presents the following Information Filed Description Number I COMPANY DATA General banner Information from Project Defaults PRINT DATE The date of printing 3 DOC NO The document number of the selected MBTP document BASE BUNDLE The Base or Bundle number of the BTP LIST TITLE The title of the document from the document s definition 6 REVISION The revision of the selected MBTP document T BTP source The document number and revision letter of the BTP document that the selected MBTP Printed for reference only HarnesSys volume 7 Manufacturing 64 x documentis based EM EFFECTIVITY The effectivities defined for the MBTP document NEXT ASSEMBLY The Next Assembly defined for the selected MBTP document The type of manufacturing report e g Coil summary Wire List by Coil Printed for reference only Chapter 5 MBTP Reports 65 Coil Summary The Coil Summary report lists the coils used for the bundle First the jumpers are listed and then each col
2. COIL SUMMARY DEM MpTP sF sPR26 FROM TO COIL HODE COIL BRADY TAPE SLEEVE LENGTH MANUF DESIGNATOR DESIGNATOR FROM TO WIRE 14C P1 1 1 WT01 06 01 100 1 M J 4 1 WT01 06 01 00 FN WT01 06 01 100 100000011000 N Manuf wire lengths this path are not equal Re organize paths so Egit From lt To Coil Number Use View Change Detail to see the designator s information Record 177 Insert 4 Edit these fields as desired Navigate using First Record Last Record Scroll Down Scroll Up buttons Use lt MB1 gt or press Tab to advance to the next field and Shift Tab to return to the previous field 5 To save your changes Press OK You receive a confirmation that the window was updated with the number of fields changed Close the screen by selecting Cancel To split a paths line 1 e to move some of the wires in the path to a new coil see Changing Wires Data below Printed for reference only HarnesSys volume 7 Manufacturing 56 Changing Wires Data 6 Place the cursor in the WIRES NUMBER field on the line of the connection with the wire s you want to change and select View Change details button The Wires window appears x W
3. dn dn Br n n n sh BR dn ge dn Ge n n SR SR SR BR SR PROJECT 4 5 METF_DOCUMENT HBTP8120500 509 DATE 2007 08 12 11 26 27 Work Order File Banner Page Printed for reference only Chapter 2 Integrating an MBTP Package Section 1 Twist Sequence 29 The Twist Sequence section of the Work Order file 15 divided into two parts The first part presents the sequence in which the segments should be twisted in short format only the order that the segments should be twisted 15 described The segments of the main path are first detailed and then those of each sub path the bundle The second part presents the same twist sequence but also details the wires In the various segments see examples below In the short format the following details are presented for each segment Segment name Starting node number End node number Number of cables in the segment THIST SEQUENCE 1 SEG 2 SEG 3 SEG 4 SEG 5 SEG END PATH START SUB SEG 1 SEG END SUB START HATH PATH B1 82 TB B6 1 62 B3 B5 PATH BEGIH PART FROH HODE FROH HODE FROH HODE FROH HODE FROH HODE EHD PART HODE FROH HODE FROH HODE EHD PART HAHE TYP 203 443 241 81 23
4. Check with your Printed for reference only HarnesSys volume 7 Manufacturing 28 The Work Order Report The Work Order report 1 composed of a banner page and the following five sections Twist Sequence List of Ist End Solders List of 2nd End Solders List of Wires Not Connected at Either End Wires Link the Following Connector Pairs and details the information for each section Banner Page Each Work Order file 1s prefaced by banner page which presents general information concerning the bundle including Project name MBTP Document name and the date the was created see example below n nh nh Gn n n n 88 n n n Da ee ee ar Ta ho sh SR SR Sh SR SR Sa DK DAC e De He He Tr Te Ta eor Ta sh SR SR Sh SR JO Gn ge Dn Tr Gr Gn SR SR SR SR SR Sh Hk Gn DAC dn De Gn Gn dc Ge Gn Gr SR SR Sh SR SR Sh Sk BUNDLE HORK ORDER 252g B B B SG S Su eoe sh sh SR SR SR DS e Dn de dr e dr eon sh SR e DR E GR n Dn
5. PARTNUMBER FROM WIRE INTEGRATE DESIGNATOR 7 DESIGNATOR 2 ALTERNATE SYSCODE SUBSYS 7 AREA CODE BUNDLE 52034 ACCESS DOOR HUD WIRE DIAG 22034 OCC LCD 29061203 ORDER NUMBER LINK OPERATION CODI MATING SUBASSY CLOCKING OCCDESC 7 U MULTI BUNDLE ROUTING AID BANDM CHARSIZE BANDTEXT SS COIL NUMBER PLUG PROG The Engineering Part Occurrence Window Press Cancel to return Printed for reference only HarnesSys volume 7 Manufacturing Printed for reference only 60 Chapter 5 MBTP Reports 61 Chapter 5 MBTP Reports HarnesSYS enables you to generate a variety of manufacturing reports which describe the contents assembly and testing of bundles The following types of reports are available Coil Summary Lists the coils Wire List by Coil Lists the wires in each coil Wire List Ist End Terminator Describes each first end connector and the wires connected to it Wire List 2nd End Terminator Describes each second end connector and the wires connected to it Hand Ringout Describes the points used to check continuity of the bundle This section describes how to create these reports and explains their contents Printed for reference only HarnesSys volume 7 Manufacturing 62 Creating MBTP Reports 1 From the Working Space select the MBTP using lt MB
6. SOLDER ENTER CRE to continue without change S for set SPECIFIC CONNECTORS as 2 nd END SOLDER to exit ras ENTER Y to identify inactive path to continue or to exit n Printed for reference only Chapter 2 Integrating an MBTP Package Selecting Inactive Paths 17 Paths to be excluded from the Work Order report are called inactive paths These inactive paths may be manually treated later 3 ENTER 77 to identify inactive path to continue or 07 to exit To continue without selecting inactive paths press Enter Go to step 5 FE To quit without making a Work Order report press Q and Enter To select inactive paths press and Enter You receive a list of Wire Links and a prompt is displayed List of wire links in the bundle prompt for inactive path s WIRES LINK THE FOLLOWING CONNECTOR PAIRS FROM_CONNECTOR 10 61TB 109TB SYP 8 F 3F G 2G 367TB TO_CONNECTOR TO_CONNECTOR TO_CONNECTOR TO_CONNECTO
7. Check notes associated with document in database ERROR Can t get released source BTP notes Check notes associated with document in database ERROR Can t get released Engineering Wire List source document Check existence of Engineering wire list in database ERROR Can t read Engineering Wire List from released file Check released file of Engineering Wire List for errors ERROR Can t read Part List source document Check existence of Part List in database ERROR Can t read Part List from released file Check released file of Part List for errors ERROR Can t get Work Process document Check issues of Manufacturing Wire List in database ERROR Can t get Manufacturing Wire List document Check issues of Manufacturing Wire List in database ERROR Can t retrieve paths nodes and segments from database Check with your ERROR Can t create Manufacturing Wire List Check existence of Manufacturing Wire List in database ERROR Can t open report file Check with your ERROR Can t open global notes of released MBTP Check notes associated with MBTP document in database ERROR Can t create Banner Page for MBTP reports Check with your ERROR Can t create 1st or 2nd end terminator reports Check with your ERROR Can t create Index Pages
8. Enter query for DESIGNATOR to and press OK 3 OUR Enter the desired From Designator Press OK To Set From Coil Number Conditions 3 7 Enter 7 from the Help Query window condition window 15 displayed Query condition 1 X Enter query for COIL NUMBER from and press OK _ Cancel _ Enter the desired From Coil Number Press OK Printed for reference only Chapter 4 Manual Changes for Manufacturing 53 To Set To Coil Number Conditions 3 8 Enter 8 from the Help Query window A condition window is displayed Query condition X Enter query for COIL NUMBER to and press OK Enter the desired To Coil Number Press OK To Display All Jumpers and Paths 3 9 Enter 9 from the Help Query window jumpers and all paths displayed Printed for reference only HarnesSys volume 7 Manufacturing 54 The Manufacturing Methods Window 1 COIL 5 5 26 FROM TO COIL NODE COIL BRADY TAPE SLEEVE LENGTH MANUF DESIGNATOR DESIGNATOR FROM TO WIRE OOOOOOOOOOOO 14 1 1 1 WTO01 06 01 2 14C Pl WT01 06 01 WT01 06 01 1 4 109400010000 11100900030 i N Manuf wire lengths in this path are not equal Re organize paths so Egit From
9. Printed for reference only Chapter 6 Release MBTP Document 77 Filed Description Number I Report Type Hand Ringout Report CONNECTOR connected to 3 FROM FER FAM The ferrule family of the From connector The number of the pin the wire comes from TRM LUG The From Termination Code field Bin code or Lug CONNECTOR The connector the other end of the wire 15 connected to 9 TO FER FAM The ferrule family of the To connector TO PIN The number of the pin the wire 15 connected to TRM LUG The To Termination Code field Bin code or Lug WIRE NAME The wire name The American Wire Gauge cross section of the wire The Suffix of the wire e g N for Ground AL for Alumel The color of the insulation used for the wire The name of the shield the wire 15 in deter mined by the Integrate Wires program The Spec Type of the wire Printed for reference only HarnesSys volume 7 Manufacturing Printed for reference only 78 Chapter 6 Release MBTP Document 79 Chapter 6 Release MBTP Document The MB TP is a document like all others regarding Configuration Control Therefore the document must go through a Release Process in order to maintain a history of modifications and alterations HarnesSYS flat file is produced for this document All inquiries about this MBTP are replied via the flat file Releasing the MBTP Document 1 Select an MBTP document to release or select Config
10. e E eR 53 Dispi AN Jumpers md orne 22 The Manufacturing Methods Window 54 Making C et adam divisa ber data oai lidem ota gave VD 55 Chane Pi i ava E 55 Chane me Mane s D 0 gt A ne 56 Changing Designator and Coil No Data 57 Printed for reference only HarnesSys volume 7 Manufacturing 4 Chapet o NID eder date 61 Creating REPOS 62 Banner PASS miel oeil 63 Sonia T T UU Tt 65 Wire To L py A NEN 67 Wire Ist Ist End Termi iray 70 Wire bist 2nd End TertmitiatoE ss u u usu ana oies 73 net ne dun OM 75 g ESA oso toas a Eia mei 76 Chapter o Release MB y t Z Zuna AT 79 Releasing the MTP Docume nt wanton uu u et RM NIS etu etai 79 OR M M 81 Printed for reference only Introduction 5 HarnesS YS Manufacturing User Manual Introduction HarnesSYS offers a comprehensive software package for manufacturing the wire bundles designed using the engineering facilities of HarnesSYS Using this package an array of reports schematic diagrams and specialized
11. 25 2HH 127 163 HIRE_HAME TO_FART TO BRAID COLOR GA TY D0000000033A 12HH 24 AA F000000018685 12HH 24 G0000000035A TG 10 L 24 0000102 TG 10 L 24 LOOO0000111A 10UYP 11HH 22 AA 10000000250 109 P 11HH 22 HO0000000028A 13H 20 AA HOOO00000080A 12HH 20 AA START HAIH PATH BEGIN PART 242 39 SEG 89 FROH HODE 37 PART TO_BRAID_COLOR GA TY H00000002 12D 11 L 24 AC 00000002 13 2 TYL 24 C HO000000425A T8TB 11 L 24 C START HAIH PATH BEGIH PART HAHE 12H 40 SEG HAHE B15 FROH HODE 133 41 SEG B17 FROH HODE 127 END HAIH PATH PART 10H COIL HO BRAID COLOR Section 1 Twist Sequence Full Format Printed for reference only 2h AHH HarnesSys volume 7 Manufacturing Mode 32 me 1 1 Printed reference only Chapter 2 Integrating an MBTP Package 33 Section 2 List of 1st End Solder The List of Ist End Solder section of the Work Order file details the starting first end connectors The connections described in this section should be made before assembling the The following information 15 detailed for each Ist end connector PART NAME The part designator of the Ist end connector COIL_NO The coil number of the segment BRADY TAPE COLOR The Brady tape color DIAMETER The combined diameter of all the wires connected to
12. the Ist end connector no FER The number of ferrules attached to the Ist end connector connector connector The number of wires attached to the Ist end connector The following information is detailed for each wire connected to a Ist end connector WIRE NAME The name number of the wire The Ist end connector pin number to which the wire is connected SEQ_NO The sequence number of the wire soldering sequence LAST STATUS Printed reference only HarnesSys volume 7 Manufacturing IM LIST 1 st E H D S O L DER PART COIL BRAID COLOR DIAHETER inch JUH CAB HIR I 1 10HH 0 376 O 26 29 SEQ HO LAST C HIRE C SLEEVE GA TY 81 52 53 STATUS C0000000459E K 0 18 C0000000460E H 0 BLE 18 CF0000004058B H 24 BA 00000000032 0 2RED 24 F0000000185A F 0 24 GO0000000001 G 0 1BRH 24 AA 10000000003 D JORG 24 L0000000008D E 0 24 A A L0000000109 C V 0 18 LOO00000126T Y 0 22 L0000000220D H BLK 24 10000000221 0 22 AA 10000000223 T 0 30RG 22 10000000225 0 22 10000000220 F JHHT 22 AA L0000000230C 8 BLK 22 LOO00000260cC D 0 JHHT 24 000000001 0 20 AA H0000000003C B 30RG 20 AA H0000000005 C C 24 H000000000
13. 0024 020 c 4 001 J P F SGE ce 473 ae J L 154 20 28 a d N4z1 WTF LD2 e eB a eF D 24B aP EZBI 15 E aeP DD 24C a ed L154 16 ec E a Find Cancel Cancel Selecting Path Conditions Select the desired path and press OK To Set From Conditions 3 3 Enter 3 from the Help Query window condition window 16 displayed Enter condition for from First Terminator Indicator F first or P partial or N null and press OK L1 Enter F for First P for Partial or N for Null Press OK Printed for reference only Chapter 4 Manual Changes for Manufacturing 51 Set F T I Conditions 3 4 Enter 4 from the Help Query window condition window 1 displayed T query condition ed Enter condition for to First Terminator Indicator F first or P partial or N null and press OK LOK Enter F for First P for Partial or N for Null Press OK To Set From Connector Conditions 3 5 Enter 5 from the Help Query window condition window 15 displayed Query condition x Enter query for DESIGNATOR from and press OK EN Enter the desired To Designator Press OK Printed for reference only HarnesSys volume 7 Manufacturing 52 To Set To Connector Conditions 3 6 Enter 6 from the Help Query window A condition window is displayed Query condition X
14. 5 MBTP Reports 73 Wire List 2nd End Terminator The Wire List 2ndEnd Terminator report describes each second end connector and the wires connected to it OPEN DOCUME WIRE LIST 2nd E TERMIN POC WIRING DEPARTMENT A TEAM ASSY ID 53012 IN COND HIRE LENGTH BRANCH PIN WIRE NAME H SU COLOR FAM CIR F OF FER REF SEC SOLDR NO IS T C FERRULE BRNC PIN SEQ n 25 Description Part Number ot lt C Angle GRA FROM WIRE INTEGRATE REF 1241 124 1241 102 HH16A 1241 gt 4 IBA 102 HH16B 1241 102 HH16C 1241 193 HHI7A 1241 103 17 124 103 17 1241 104 124 104 IHH18B 1241 I gt NOTE 6 7 104 18 1241 JN Wire List 2nd Terminator Report Page Each data page of a Wire List 2nd Terminator report contains the following information Printed for reference only HarnesSys volume 7 Manufacturing 74 Filed Description Number ASSY ID The base number of the bundle Report Type Wire List 2 end Terminator report 3 BRANCH The Branch Letter of the part The number of the pin the wire 15 connected to WIRE NAME T momo the wire _____ Th
15. Build to Package Project Defaults Manufacturing Manufacturing Methods Manually Update Manufacturing Data Connections Screen change connections data Wire Screen Change wire data Manufacturing Parts Occurrence Screen change designator data Printed for reference only Build To Package Config Ctrl Sys Build to Package Define manufacturing Integrate Work Order Report Document Config Ctrl Sys Release MBTP View Define Manuf Defaults Y Jig Diagram x 2D Routing Jig Arrange Jig Diagram Manufacturing Reports HarnesSys volume 7 Manufacturing Engineering amp Manufacturing Operations HarnesSYS Manufacturing User Manual contains 6 chapters Setting Manufacturing Project Defaults Chapter 1 describes the Manufacturing project defaults provides examples of the parameters and explains how to set them Integrating an MBTP Chapter 2 explains how to integrate a Manufacturing Build to Package document in order to produce a Work Order file This chapter also describes each section of the Work Order file Making Modifications Chapter 3 explains how to incorporate design changes into manufacturing after the manufacturing reports h
16. Config Ctrl Sys Release Release Wire List Parts List Config Ctrl Sys Build to Package Select new issue of component documents Modify Config Ctrl Sys Release Modified Build to Package Engineering Manufacturing Build To Package Jig Config Ctrl Sys Diagram Define Change Report manufacturing Build to Package 2D Routing Jig Document Sy Arrange Jig Manufacturing Methods Diagram Manually Update In View Manufacturing Data ate Connections Screen Manufacturing change connections data Work Order Report Reports remains unchanged Wire Screen Change wire data Manufacturing Parts Occurrence Screen change designator data Incorporating Engineering Changes into the Manufacturing Data Base Printed for reference only Chapter 4 Manual Changes for Manufacturing 47 Chapter 4 Manual Changes for Manufacturing This chapter explains how to manually change manufacturing data including changes in connections for example Coil No Brady Tape changes in wires e g Ferrule Length Sleeve Code Wire Length changes in designators e g Tetra Etch Brady Tape First Terminator These changes are made using a number of screens the screen displayed determines the type
17. To Coil Humber Use View Change Detail to see the designator s information Record 1 7 Insert The Manufacturing Methods Window The Manufacturing Methods window 1s sorted as follows first the jumpers are listed and then the remaining paths are listed according to Coil No The Manufacturing Methods window presents the following information for each connection in the bundle shaded fields may be changed First Terminator Indication F for first end terminator P for Partial end terminator or blank This field may be changed DESIGNATOR The From and To designators Read only COIL NO The coil numbers of the From and To designators This field may be changed Refer to the description of the COIL MODE field above NUMBER OF The number of wires between the two designators Although this WIRES field is read only you can advance to the Wires window from this field See explanation below BRADY TAPE The color and number of the Brady tapes of the From and To designators These fields may be changed SLEEVE LEN The sleeve length of the From and To designators This field may be changed However sleeve lengths can be entered only for single wires Printed for reference only Chapter 4 Manual Changes for Manufacturing 55 Making Changes Changing Paths Data explained above the Manufacturing Methods window allows you to change the following fields COIL BRADY and SLEEVE LEN
18. distance between the last braid stop and the breakout point see F last braid Ist braid part edge gt seu breakout Printed reference only Chapter 1 Setting Manufacturing Project Defaults 13 There are two Special Cases which describe minimum distances Ferrule Area and Braid Stop the minimum distance between the end of the ferrule area and the first braid stop for two specific cases see G if the ferrule 15 attached to EMI back shell if the wires are shielded 1st braid lt ferrule area 77 part edge ft Part Edge and Braid Stop the minimum distance between the part edge the first braid stop for the following special cases Reference Connector Splice Area Wire Gauge Larger Than 18 More than 14 Wires Less Than 15 Wires 5 Press OK to save your settings and close the Manufacturing Project Defaults window The Project Defaults window returns 6 Press OK on Project Defaults window to save your settings and close the Project Defaults window Printed for reference only HarnesSys volume 7 Manufacturing Printed for reference only 14 Chapter 2 Integrating an MBTP Package 15 Chapter 2 Integrating an MBTP Package This chapter shows how to integrate a Manufacturing Build to Package MBTP document in order to produce a Work Order report which details the procedure to be followed to prepare a bundle Operating Instructi
19. distinct group of wires e g together w COLOR The color of the Brady tape defined for the coll 12 SLV LEN INCH The length of protective sleeving for wires not defined as hook up wires Whether a wire 15 hook up wire or not 15 determined via the Wire Specifications program The status of the selected MBTP document The date the report was produced 15 Footer The footer defined for reports via Project Defaults In the example above the footer was defined as page Printed for reference only Chapter 5 MBTP Reports 67 Wire List by Coil The Wire List by Coil report describes each wire the bundle This report is broken down and sorted according to Coil No see example below SLEEVE LENGTH ISTRIP FERRUEE SLEEVE F IN FROM F COD LENGTH BRANCH CODE IF IS MM MM CM CM IFROMITO 18 Second Solder Jumpers JP1 1201 1BRN A Al JP2 1201 2RED A AI l NO OF CONDUCTORS 0 NO OF JUMPERS OF CABLES 0 IHH15A 1241 5GRN 11 401 9 00 IF HH16A 1241 6BLU A Al ll 40 0 00 IF HH17A 124 7 LT A AI 1 40 0 00 IF HH18A 12
20. the Bin Code Lug Part Number Quantity and Description of each terminator e g splice in the bundle Parts List describes the parts used in the bundle 2D Routing a two dimensional not to scale layout drawing of the bundle Jig a two dimensional full scale 1 1 layout drawing of the jig required to produce the bundle For details on how to define a BTP document see your Configuration Control user manual in Volume 6 of the HarnesSYS user documentation Printed for reference only HarnesSys volume 7 Manufacturing 6 Manufacturing Build to Package Documents MBTP After an Engineering is created manufacturing personnel can build their own Manufacturing Build to Package based on 1t An MBTP document 16 integrated order to create Work Order file which details the assembly of the bundle see Chapter 2 Integrating an The information presented can be customized to meet specific manufacturing needs using forms activated via the Manufacturing Methodology program For details on how to define an MBTP document see your Configuration Control user manual in Volume 6 of the HarnesSYS user documentation Manufacturing Operations The following operations are involved in the manufacturing process defining the MBTP document see your Configuration Control System manual for details updating manufacturing defaults for the project Brady tape additional wire length needed for Brady tape min
21. 00000426 24 004 26 82 H00000002 13A 24 002 21 143H 8 ITE 000000400 24 004 28 15 3H H0000000001D 20 29 H0000000003D 18 AA 30 000000026 18 AA 31 14 H0000000002 C 20 32 H0000000004C 20 H0000000002D H0000000004D 00000002 0000000006 0000000010 0000000013 Section 4 List of Wires Not Connected at Either End Printed for reference only 40 Chapter 2 Integrating an MBTP Package 41 Mode 1 1 Printed for reference only HarnesSys volume 7 Manufacturing 42 Section 5 Wires Link the Following Connector Pairs This section of the Work Order file shows all the connector pairs that are linked 1 at least one wire 1s connected between them The following information is detailed for each wire link FROM BRADY TAPE COLOR FROM_END_SOLDER TO_END_SOLDER NO_WIRES NO_CABLES A sequential reference number for the wire link for this section of the file only The starting connector The terminating connector The braid color of the From connector The braid color of the To connector The Coil number of the From connector The Coil number of the To connector The status of the From connector Ist end or 2nd end The status of the To connector Ist end or 2nd end The number of wires in the link The number of c
22. 1 gt and press the View button list of standard report types 15 displayed Select Standard Reports O Coil Summary Wire List By Coil Wire List 1st End Terminator Wire List 2nd End Terminator Hand Ringout Wire Card End1 Wire Card Wire Connector Sort 2 Select your required reports and press OK The selected reports are generated and a message window confirming the process and displaying the name of the report file appears see example below Harnessys Information 1 MBTP Report Is Saved Your Private File CHK MBTP MULT 1710 001 rep 3 Press OK to close the message window Printed for reference only Chapter 5 MBTP Reports 63 Banner Page Each report Is prefaced by banner page which presents general information about the bundle the MB TP document and the report itself see example below Kk K K K keke eA REE EAA KEKE AKER EEK KEKE AEE KER EK EK eK FABULOUS FLYING MACHINES LTD RELEASED DOCUMENT 2006 12 03 12 10 32 ENGINEERING CENTER PRINT_DATE 2007 08 01 X x 2 AVIONICS ENGINEERING DOC NO 5 034 1 BASE BUNDLE 22034 TITLE 6 REVISION LT BTP source DEM BTP SNML034 1 REVISION LT EFFECTIVITY NEXT ASSEMBLY 0
23. 4 8GRY A AJ 11 40 0 00 IF HH1A 124 IHH 1BRN AAA F 76 0 00 Ji 7 00 AA CA IHH2A 1241 2RED AAA A F 11 161 0 00 IF HH4A 124 IHH 4YEL AAB A F 11 76 0 00 41 7 00 IF HH5A 1241 5GRN AAB A F 11 161 9 00 6 124 BL 6BLU AAC F 11 65 0 00 41 7 00 HH7A 1241 A F 65 0 00 IF HH9A 1241 9WHT AAD A F 11 65 0 001 1 37 00 AA CB IF HH10A 124 BL OBLK AAD A F U 65 9 00 AA CB IF J 8 18 Report sorted according to Coil No Wire List by Coil Report Page Each data page of a Wire List by report contains the following information Printed for reference only HarnesSys volume 7 Manufacturing 68 Filed m 202 Number kau ee mmm 0 Cr ee uM 7 document peer 7 document WIRING Details describing the department to which the 15 assigned Project Defaults 6 The base number of the bundle amp AWG American Wire Gauge Css Ron of the wire 9 SUFF The Suffix of the wire e g for Ground AL for Alumel V V WAn FAM The name of the shield the wi
24. 7D L 0 TVLT 18 AA H0000000009 C J 0 20 H0000000014D K AYEL 16 00000124 J 0 AXEL 22 AA 0000000171 c 0 24 0000000009 z TH 16 E 005 0000000019 0 TH JHHT 16 E 005 00000002 126 0 HH 2RED 24 AB 005 0000000400 4 0 EL BLE 24 A B 005 See e M illustration on next PART COIL HO BRAID COLOR DIAHETER inch no FER UH HIR page V 242H 24 8YL 0 140 oO 10 1 3 SEQ LAST C HIRE C SLEEVE GA TY 81 82 83 STATUS H0000000212D T4 0 HH 2RED 24 C 003 H0000000213E T1 BL JORG 24 C 003 HO000000425A T8 0 OR 24 003 ERROR PPH DATA HISSING FOR PART 242 COIL BRAID COLOR DIAMETER inch no FER JUH CAB HIR 12H I 28 2HH 142 0 1 1 1 NAME PIN SEQ NO LAST C WIRE C SLEEVE GA TY 51 62 S3 STATUS 3P00004 LEE H0000000016A 1 0 6BLU 18 Section 2 List of Ist End Solder Printed for reference only Chapter 2 Integrating an MBTP Package 35 Owl Mode 1 1 Printed for reference only HarnesSys volume 7 Manufacturing 36 Section 3 List of 2nd End Solder The List of 2nd End Solder section of the Work Order file details the second end connectors After performing the first end connections described in the previous section the connections described in this section should
25. A TY 51 82 53 STATUS 0000000400 8001 0 BL OBLK 54 AC 004 H0000000400A 8001 0 BL OBLK 24 AB 005 see illustration ERROR PPH DATA MISSING FOR PART 81TB me page COIL BRAID COLOR DIAHETER inch no FER JUH CAB 8G 4 12HH 0 197 19 19 eee x x u u T Ts Tx T i HIRE SEQ HO LAST C HIRE C SLEEVE GA TY 51 82 53 STATUS 2000000000324 L 0 RED 00000000334 0 30RG 24 A A F0000000014A R 0 24 A A F0000000185A H 0 5GRH 0000000186 0 BBLU 0000000001 V 0 1BRH G0000000002A T 0 RED 24 H0000000089A 8 0 20 H0000000002A P 0 RED PART_NAME COIL_NO BRAID COLOR DIAHETER inch no FER JUM CAB HIR 143H 22 951 0 140 10 11 13 HIRE SEQ LAST C HIRE C SLEEVE GA TY S1 82 83 STATUS H0000000212H T4 0 HH 2RED 24 A C 004 0000000400 T1 0 BL OBLK 24 AC 004 H0000000426A T8 0 OR 6BLU 24 AC 004 Section 3 List of 2nd End Solder Printed for reference only HarnesSys volume 7 Manufacturing 38 Mode 1 1 Printed reference only Chapter 2 Integrating an MBTP Package 39 Section 4 List of Wires Not Connected at Either End This section of the Work Order file describes the wires for which both connectors have been defined as the second end co
26. COIL BRAID COLOR TO HODE HO CABLES TO HODE HO CABLES TO HODE HO CABLES TO HODE HO CABLES TO HODE HO CABLES COIL BRAID COLOR TO HODE HO CABLES TO HODE HO CABLES COIL HO BRAID COLOR EE 40 SEG NAHE 41 SEG END HAIH PATH START HAIH PATH 815 817 BEGIH PART HAHE FROH FROH HODE PART COIL BRAID COLOR TO HODE HO CABLES TO HODE HO CABLES COIL BRAID COLOR Section 1 Twist Sequence Short Format Printed for reference only 25 2HH 127 1 183 0 26 IHH HarnesSys volume 7 Manufacturing 30 In the full format the following information 1s detailed for each segment BEGIN PART NAME The part designator of the Ist end connector NO The coil number of the segment BRADY TAPE COLOR The Brady tape color SEG NAME The name of the segment FROM NODE The node where the segment starts TO NODE The node where the segment end NO CABLES The number of cables in the segment where a cable 15 a lone wire or a distinct group of wires e g twisted or shielded together In the full format the following information 15 detailed for each wire WIRE NAME The name number of the wire TO PART The part designator of the ending connector TO BRADY TAPE COLOR The Brady tape color of the ending connector GA TY The gauge and type of wire 51 52 53 The twist or shield family to which the wire belongs Printed for referenc
27. D SOLDER SET CONNECTOR 2G to 2 nd END SOLDER SET CONNECTOR 82 to 2 nd END SOLDER integration SET CONNECTOR Z8TB to 2 nd END SOLDER process SET CONNECTOR 6YP to 2 nd END SOLDER SET CONNECTOR 5H to 2 nd END SOLDER SET CONNECTOR 36 to 2 nd END SOLDER SET CONNECTOR 77TB to 2 nd END SOLDER SET CONNECTOR 61TB to 2 nd END SOLDER SET CONNECTOR 109TB to 2 nd END SOLDER SET CONNECTOR 13M to 2 nd END SOLDER SEI CONNECTOR 11H to 2 nd END SOLDER SET CONNECTOR 6M to 2 nd END SOLDER SET CONNECTOR 14 to 2 nd END SOLDER SET CONNECTOR 76 to 2 nd END SOLDER SET CONNECTOR 143H to 2 nd END SOLDER Go to Step 12 Printed for reference only HarnesSys volume 7 Manufacturing Automatic Selection By Number of Wires 11 SET CONNECTOR 78 SET CONNECTOR 10 SET CONNECTOR 82 SET CONNECTOR 15 SET CONNECTOR 26 SET CONNECTOR SET CONNECTOR 5 PROGRAM SELECTED PROGRAM SELECTED integration PROGRAM SELECTED process PROGRAM SELECTED MR TB 9v p TB TB p CONNECTOR CONNECTOR CONNECTOR CONNECTOR to to to to to to to PROGRAM SELECTED CONNECTOR PROGRAM SELECTED CONNECTOR SET CONNECTOR 6M to PROGRAM SELECTED CONNECTOR PROGRAM SELECTED CONNECTOR Go to Step 12 z nd END SOLDER 2 nd END SOLDER Z7nd END SOLDER Z7nd END SOLDER Z nd END SOLDER 2 nd END SOLDER 2 END SOLDER 109 for 1 st 8G for 1 st 22F for 1 s
28. ER 0 109 NUMBER_OF_WIRES 1 prompt for another SELECT CONNECTOR NUMBER connector CR to program default or Q to exit 2 number 8 Note this 15 a similar list and the same prompt as shown in Step 6 response to the SELECT NUMBER prompt To continue without selecting starting connector automatic selection press Enter You to Step 9 To quit without making Work Order report press Q and Enter Enter the number of another connector you want to set as a starting first end connector and press Enter Repeat Step 8 above for all the starting connectors you want to specify until the integration 1 completed Go to Step 12 Printed for reference only Chapter 2 Integrating an MBTP Package Automatic Selection By Diameter 9 The following prompt appears ENTER lt CR gt to automatically select connector by diameter toU to automatically select connector by number of wires 1 to exit aus Press Enter to automatically select by diameter Go to Step 10 Press 1 and Enter to automatically select by number of wires Go to Step 11 10 The integration process 16 performed and detailed the message window PROGRAM SELECTED CONNECTOR for 1 st END SOLDER SET CONNECTOR 23F to 2 nd END SOLDER SET CONNECTOR 81 to 2 nd END SOLDER SET CONNECTOR 8G to 2 nd END SOLDER SET CONNECTOR 109 to 2 nd END SOLDER SET CONNECTOR 15TB to 2 nd EN
29. IRES IN _ MBTP IZK 2003 TmuMBER FHemn Term NFS FER FER SLV TE SIV WIRE NAME Color Fam Typ zm 1 Spec NUMBER Eng WIR m RUN LETTER Mn H CahidaM 2 CONNECTOR PIN CODE LEN LEN CODE AUTHORITY NBM amp TH Hooooo000s04 ag GND4 Bo02 EE LE 438 9 ORG L IL RE ee QI ie 0000000092 4 __ __ GND4 B002 EI QE Gt I EL 4389 ORG L IL IT EI LILIL e a LIDDIIJ LJ G 1I L jj SS gt L P gt kae i J Cancel Kl E kuwwwsr uwnWnmAi On the top line the Wires window displays general Information read only about the MBTP document and selected connection The rest of the window details the wires that are In the selected connection The Wires window allows you to change the following wire related fields NES Not First Solder N for a first solder otherwise blank for From and To Connector FER CODE The ferrule code of the wire FER LEN The ferrule length of the wire SLV LEN The sleeve length of the wire The length of the wire Update the fields as desired To save your changes press OK You receive a confirmation that the records were updated To close the screen press C
30. Project LENGTH Defaults for the wire This 1s the length from the end of the wire to the start of the ferrule Manually entered via the Wires screen see Manual Changes for Manufacturing earlier in this manual 25 BRANCH The Branch Letter of the part This indicates the area of the jig Printed for reference only Chapter 5 MBTP Reports 69 where the part should be placed 0000 The sleeve code for the wire Manually entered via the Paths screen see Manual Changes for Manufacturing earlier in this manual First End Terminator F appears for first end terminator and P for partial otherwise this field 1s blank Not First Solder N appears for a first solder otherwise this field 15 blank Before the wires in each bundle are described using the fields explained above the following information describing the coil is given NO OF CONDUCTORS The number of conductors or individual wires belonging to the coil NO OF The number of jumpers belonging to the coil JUMPERS NO OF CABLES The number of cables 1 lone wires or distinct groups of wires belonging to the coil Printed for reference only HarnesSys volume 7 Manufacturing 70 Wire List 1st End Terminator The Wire List Ist End Terminator report describes each first end connector and the wires connected to it WIRING DEPARTMENT A TEAM IA 71 PIN WIRE NAME W SU COLOR FAM CIR F IFERIREF
31. R TO_CONNECTOR TO_CONNECTOR TO_CONNECTOR TO_CONNECTOR TO_CONNECTOR TO_CONNECTOR TO_CONNECTOR TO_CONNECTOR TO_CONNECTOR TO_CONNECTOR SYP 8 SYP 109 8 109 P 367TB E 35 3 6 FROM_CONNECTOR FROM_CONNECTOR 12M 13M SELECT NUMBERS e g 1 3 8 lt cr gt TO_CONNECTOR TO_CONNECTOR 6 3 In response to this prompt enter numbers of paths you want to exclude the inactive paths separated by commas and then press Enter To continue without selecting inactive paths press Enter To quit without making a Work Order report press Q and Enter Printed for reference only HarnesSys volume 7 Manufacturing 18 Selecting Starting Connectors D The following prompt is displayed ENTER Y to select starting connector lt CR gt to program default or Q to exit At this point you can manually select the first end connectors Step 6 allow the program to automatically select the starting connectors according to the diameters allow the program to automatically select the starting connectors according to the number of wires in them To manually select starting connector press Y and Enter Go to Step 6 To quit without making a Work Order report press Q and Enter Press Enter to continue Go to Step 9 Printed for reference only Chapter 2 Integrating an MBTP Package 19 Manuall
32. SEC SOLDR IG FF NO S T C FERRULE WIRE SEQ CM 19 lan IK AA IL AA IN 10 10 Spare Pin 9 HH10A HH15A HH16A gt NOTE 4 HH17A Spare Pin HH18A Spare Pin Part Number Qt 2 2 76 I SHAAA 3 1 4 4 76 5 5 76 AAD CB 6 6 65 IAADICB 17 7 65 SHAAC 8 1 9 BL AAD 19 10 65 IBL 10 11 65 01 12 40 BA 102 13 40 03 14 40 15 04 16 40 17 Wire List Ist End Terminator Report Page Each data page of a Wire List Ist End Terminator report contains the following information Printed for reference only Chapter 5 MBTP Reports 71 Filed Description Number O Wire List 1 end terminator report The Branch Letter of the part This indicates the area of the jig where the part should be placed 5 WIRENAME _____ The wire name _ 00005 BUNDLE ASSEMBLY The document PUE of the jig diagram in the NO MBTP The American Wire Gauge cross section of the wire The Suffix of the wire e g for Ground AL for A
33. VISION Commercial Aircraft Group ISRAEL AIRCRAFT INDUSTRIES LTD Printed for reference only Table of contents 3 Table of Contents Inttoduc HOM ee ren 5 Documents required for Manufacturin 5 2D STAINS ___________ __ 5 Jis or Porm Board D nee 5 BTP uuu u uu m ee I nun nu ie 5 Manufacturing Build to Package Documents MB TP 6 Man tacturing Operations uuu eta ieee 6 Chapter 1 Setting Manufacturing Project Defaults 9 Operatie IS COONS unun uuu nupun dt te 9 Brady Tape ua tuspa mua a tiennent diese 11 Brid Derat Siere N 12 Chapter 2 Integrating an MB EP 15 CETOTIS nn seas 15 Creating the Work Order REPO 2 3 6 0 mod 16 Selectine Inacuve Patbs nes uya neue 17 COMMS 18 Manually Selecting Starting Connectors 19 Automatic Selection Dy au oi tente 21 Automatic Selection By Number of Wires ss 22 Updati
34. ables the link Printed for reference only Chapter 2 Integrating an MBTP Package 43 HIRES LINK THE FOLLOWING CONHECTOR PAIRS for reference only see no FROH FROH BRAID COLOR FROH COIL FROH EHD SOLDER HO HIRES illustration TO TO BRAID COLOR TO COIL TO EHD SOLDER HO CABLES next page Section 5 Wires Link the Following Connector Pairs Printed for reference only HarnesSys volume 7 Manufacturing 44 Mode 1 1 4 3 s be 1 Printed for reference only Chapter 3 Making Modifications 45 Chapter 3 Making Modifications This chapter refers to bundle that has been defined created by the manufacturing procedures in Chapter 2 and details how to incorporate engineering changes such as adding wires to such bundle This procedure can be broken down into seven stages as follows Stage 1 Make the desired changes in the wiring diagram e g add wires exchange parts used etc Stage 2 Integrate the updated wiring diagram using the Wire Integration program This updates the wires data base Wires List and parts data base Parts List as required in accordance with the changes made Stage 3 Release the new Wires List and or Parts List whichever was changed Stage 4 Update the definition of the BTP document by selecting the new issue of the Wires List or Parts List whichever was changed Stage 5 Release the m
35. ady Tape Working Report Below 1 an example of the message window that 1 opened g MBTP Integration _ 23 PROJECT 4A5 DOCUMENT 8120500 509 START of UPDATE BRADY TAPE COLOR RETRIVE PATHS FROM DATABASE PUT BRADY_TAPE DATABASE ENTER C for COMMIT 757 to STOP Updating Printed for reference only HarnesSys volume 7 Manufacturing 26 Creating a Working Report generate a Working Report containing the information displayed the Manufacturing Methods window choose Working Report in the Integrate MBTP window The program generates the report Integrate MBTP select Operations Ol Create Work Order Update Brady Tape Working Report Below 1 an example of the message window that 1 opened CHK CHK MBTP 1301 001 PROJECT DOCUMENT MBTP WORK ORDER REPORT Process terminated o k See report CHK MBTP 1301 001 rep in your private directory To close window type lt CR gt Printed for reference only Chapter 2 Integrating an MBTP Package 27 Error Messages Below 1s a list of error messages that you may receive when producing this report The second line of each error tells you what to do to fix the problem ERROR Can t get names and issues of MBTP source documents Check existence of source documents and their issues in database ERROR Can t get document notes of MBTP
36. ancel You return to the Manufacturing Methods window Sometimes it is necessary to transfer a wire or wires from one coil e g Coil No 6 to another coil e g Coil No 6A To do this enter the new coil number in the COIL field of the wire s and Commit OK your changes The Methods screen will automatically be updated and split into two groups the wires which are still defined for the original coil Coil No 6 and those defined for the new coil Coil No 6A This procedure can be used to handle backtwists Printed for reference only Chapter 4 Manual Changes for Manufacturing 57 Changing Designator and Coil No Data 9 From the DESIGNATOR or COIL NO field select View Change Details The Manufacturing Methods Manufacturing Part Occurrence window for the selected designator 15 displayed MANUFACTURING METHODS Ex MANUFACTURING PART 2 2003 DESIGNATOR 01 2001 PART HUMBER ETCH COIL HUH 7 LET FIRST MAJOR SUB DEGREE 0 Data Base Information not from flat file pee specication Vccurence Manufacturing Part Occurrence Window The Manufacturing Part Occurrence window allows you to update the following fields BRADY TAPE The Brady tape color defined for the designator TETRA ETCH The Tetra Etch of the designator COIL NO The Coil No of the designator BRANCH LET The branch letter of the
37. ave already been produced Manual Changes for Manufacturing Chapter 4 explains how to manually modify manufacturing data MBTP Reports Chapter 5 describes additional manufacturing reports and explains how to produce them Release MBTP Chapter 6 shows how to release an MBTP Document Printed for reference only Chapter 1 Setting Manufacturing Project Defaults 9 Chapter 1 Setting Manufacturing Project Defaults This chapter shows how to set manufacturing default values related to the braids and Brady tapes used the project Operating Instructions In order to set the manufacturing defaults for the current project follow these steps 1 Select Maintenance gt Project Defaults The Project Defaults window appears Set Project Defaults for Project DEM iise Deiaults of Existing Proiect Defaults for Graphics Administration Manufacturing Reports Retrofit The Project Defaults Window 2 Press Manufacturing Printed for reference only HarnesSys volume 7 Manufacturing The Manufacturing Project Defaults window 1 displayed Defaults for brady tapes Defaults for braids stops ferrule area etc Manufacturing Defaults for DEM Run Letters Braids Maximum Retained per Wire General Defauits Number of Characters in One Set Minimum Distance Between Part Edge and Ferrule Area 2 5 4 2 Levels of Braid Stops 2 5 4 Eng Manuf Max Wire Dif
38. be made as the jig is assembled The following information is detailed for each 2nd end connector PART NAME The part designator of the 2nd end connector COIL_NO The coil number of the segment COLOR The combined diameter of all the wires connected to the 2nd end connector The number of ferrules attached to the 2nd end connector no JUM The number of jumpers attached to the 2nd end connector The number of cables attached to the 2nd end connector The number of wires attached to the 2nd end connector The following information is detailed for each wire connected to a 2nd end connector WIRE NAME The name number of the wire The Ist end connector pin number to which the wire is connected SEQ NO The sequence number of the wire soldering sequence LAST STATUS Printed reference only Chapter 2 Integrating an MBTP Package rue LIST 2 E H D 5 OLDER ieee PART HO COLOR DIAHETER inch no FER JUH CAB 23 2 1 YL I 0 178 10 1 2 SEQ HO LAST C HIRE C SLEEVE GA TY 81 52 83 STATUS 0000000009 0 JHHT 16 EA 005 0000000019 0 QWHT 16 EA 005 ERROR PPH DATA MISSING FOR PART 23F PART COIL BRAID COLOR DIAHETER inch no FER JUH CAB HIR 81TB 3 13 L 0 182 0101117 HIRE SEQ HO LAST C HIRE C SLEEVE G
39. connector indicating the area of the jig that it is to be placed in as determined in the Jig FIRST TERM First Terminator if the designator is a first terminator F is entered here otherwise this field is left blank PPN The key of the soldering sequence for inserting the wires into the pins of the connector After you have updated this window press OK to return to the Manufacturing Methods window If you have no changes press Cancel Printed for reference only HarnesSys volume 7 Manufacturing 58 You can retrieve for reference only the Part Specifications Window step 10 and Engineering Part Occurrence Window step 11 of the designator 10 Press See Part Specification button The Part Specification window 1 displayed MANUFECTURING METHOD xj PART SPECIFICATION Data base information not from flat file PART NUMBER VENDOR CODE DESCRIPTION SPEC LCD DRAWING NUMBER COOLING ACDC COOLTYPE LOAD VOLT 7 BINKEY 1 HZ BASE PLUG PROG NO PART TYPE 7 SHELL SIZE CONTACT KEY TYPE The Part Specification Window Read Only Press Cancel to return Printed for reference only 11 Chapter 4 Manual Changes for Manufacturing 59 Press See Part Occurrence button The Engineering Part Occurrence window 16 displayed MANUFECTURING METHOD ENGINEERING PART OCCURRENCE Data base information not from flat file occKEY zz
40. documents can be produced to optimize the manufacturing process and make maximum use of the engineering and design data in the system This introduction describes the documents and components required for Manufacturing the Manufacturing Operations Documents required for Manufacturing 2D Routing Diagrams A 2D Routing diagram shows the layout of the bundle as it is manufactured on the jig board including all the branches and terminator parts in the bundle branch sizes etc Since they are not really intended for manufacturing 2D Routing diagrams are not to scale Jig or Form Board Diagrams A Jig diagram 15 2D full scale drawing of the jig or form board required to produce harness It includes all the information needed including Clocking Angles labels protective devices etc Jig Drawings are automatically obtained by integrating 2D Routing diagrams created by HarnesSYS or flattening 3D Routing diagrams imported into HarnesS YS Jig diagrams are also used as Input to Integration programs that calculate the length of the wlres 1n the bundle and the diameter of wires and segments Build to Package BTP Documents Build to Package document also called an Engineering BTP contains all the documents needed to produce a particular bundle including Wire List describes the wires used the bundle including end terminators the Type Circle Part Number Quantity and description of each wire It also details
41. e ENGINEERING DIVISION Commercial Aircraft Group ISRAEL AIRCRAFT INDUSTRIES LTD HarnesSYS User Manual for MANUFACTURING HarnesSys volume 7 Manufacturing Notices The information contained this manual 15 believed to be accurate and reliable However Israel Aerospace Industries Ltd assumes no responsibility for any errors omissions or inaccuracies whatsoever Information in this document is subject to change without notice and does not represent a commitment on the part of Israel Aerospace Industries Ltd IAI The software and or data base described in this document are furnished under a license and or agreement The software and or data base may be used or copied only in accordance with the terms of such license and or agreement It is against the law to copy the software on any medium except as specifically allowed in the license and or nondisclosure agreement The purchaser may make one copy of the software for backup purposes No part of this document and or data base may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying recording or information storage and retrieval systems for any purpose other than the purchaser s personal use without the express written permission of 2007 Israel Aerospace Industries Ltd All rights reserved Pub Number TSN140 930394 Issue Revision 0 Version 16 00 Prepared by Ill ENGINEERING DI
42. e Suffix of the wire e g N for Ground AL for Alumel CLR The color of the insulation used on the wire If the wire 1s twisted and no color was entered TW may appear document 13 CIR NO The type of wire according to specific work 14 5 Not First Solder N appears a first solder otherwise this field is blank COND T C The Conductor wire Terminating Code WIRE OF FERRULE Ferrule wire name D REF BRNC The branch letter of the other side of the wire selected MBTP document LENGTH The length of the wire 23 WIRING DEPARTMENT Details describing the department to which the MBTP 15 assigned The report 16 divided according to 2nd end connectors Note that each section has a list of the parts in it The main part is displayed first followed by the secondary parts Each part is described by the following fields Printed for reference only Chapter 6 Release MBTP Document 75 Do Number Specifications The designator of the connector The part number of the connector 24 Qty The quantity of the part described according to designator that 1s used the assembly C Angle The clocking angle of the connector Notes The standard notes attached to the MBTP document Parts list and Wire list are printed a Separate page This page appears following the Ist End Terminator report no 2nd End Terminator report was made or following the 2nd End Termi
43. e only Chapter 2 Integrating an MBTP Package E U E H C E full format 31 CO IL HO BRAID COLOR TO HODE HO CABLES 81 52 83 START MAIN PATH PART NAHE 5YP 1 SEG 81 FROH HODE 203 TO PART TO BRAID COLOR GA TY C0000000459E 61TB IYL 18 AA C0000000460E 61TB IYL 18 A A CF000000405B 109TB 3YL 94 70000000032 12HH 24 F0000000185A c 12HH 24 0000000001 8G 12HH 24 1 0000000003 36TB DHH 24 A L0000000008D 36TB DHH 24 L0000000109 109 P 11HH 18 L0000000126T 109 P 11HH 22 L0000000220D 109 P 11HH L0000000221 109 P 11HH 22 L0000000223 109 11HH 99 L0000000225 109 P 11HH 22 L0000000229 109 P 11HH 22 L0000000230 109 P 11HH 22 L0000000269 109 P 11HH 24 0000000001 15TB HH 20 A HO000000003 15TB 20 0000000005 5M 24 H0000000007D 5M 18 AA illustration 0000000009 13H 20 on next 0000000014 JHH 18 page M a 38 START HATH PATH SEG B1 PART FROH HODE 1 COIL BRAID COLOR TO HODE 1 52 s3 COIL BRAID COLOR TO HODE HO CABLES 51 52 53 COIL HO BRAID COLOR TO HODE HO CABLES TO HODE HO CABLES AIN PATH BEGIN PART 3XYP COIL HO __ 23 13HH 17 d n n H I L2
44. fer 5 0 8 mam 5 0 8 LastBraid Stop and Cable Code ID Last Braid Stop and Breakout 2 5 4 Brady Tape Special Cases Combine Brady Tape Colors L1 No Minimum Distance Between Ferrule Range Additional Wire Length Ferrule Area and Braid Stop D fi d For First Brady Tape 0 0 nan EMI Back shell 76 2 m 50 8 efine For Next Brady Tape mm Shielded Wires 76 2 m 50 8 Brady colors Brady Tape Colors Part Edge and Braid Stop Reference Comector 203 2 mm Description 76 2 Splice Area mm full name 114 23 Metal overbraid Huge Run for new Nomex overbraid 101 6 Than 14 Wires mm Brady color Description rr Lose than 15 Wires And code Printed for reference only 10 Chapter 1 Setting Manufacturing Project Defaults 11 Brady Tape Defaults 3 The left side of the Manufacturing Project Defaults screen enables you to define defaults related to Brady tapes as described below Combine Brady Tape Colors This check box allows you to determine whether more than one Brady tape color be used on wire Additional Wire Length The length of wire to be added for the first For First Brady Tape Brady tape see below and each For Next Brady Tape additional Brady tape see B below For example 1f 1 15 to be added for the first Brady tape and 5 for each additional Brady tape and the wire has three Brady tapes a total of 1 2 5 2
45. his point you can easily specify those items you are interested in In effect this function defines filters for you to view and change manufacturing data 2 define criteria for the items to be displayed in the Manufacturing Methods window press the Help Show Condition button on the Manufacturing Methods window The Help Query window is then displayed xi In order to choose criteria for one or more paths choose a number from the left column and enter it or press the key sequence described in the right column Choose option 1 9 1 Only jumpers 2 Condition for path 3 Condition for FROM 4 for 5 Condition for FROM Connector 6 Condition for TO Connector 7 for FROM Coil Number 8 Condition for TO Coil Number 9 All jumpers and The Help Query Window 3 To select an option enter its number and press Enter The nine options are now described Printed for reference only HarnesSys volume 7 Manufacturing 50 To Display Only Jumpers 3 1 Enter 1 from the Help Query window Only the jumpers are displayed To Set Path Conditions 3 2 Enter 2 from the Help Query window The list designators window with the paths in the document 15 displayed List designators from and En and coil numbers from and to Find E From Connect To Connect Coil Nur Coil Mur 1 135 52 0024 13 16 1 0024 aeF D z4c c 18 1 0024 4 011 c d 1
46. hs Data 57 Changing Wires Data 58 Summary 67 E Error Messages 29 H Hand Ringout 78 I Integrating an MB TP 15 J Jig Diagrams 5 81 L List of 15 End Solder 35 Fnd Solder 38 List of Wires Not Connected at Either End 41 M Manual Changes for Manufacturing 49 Manufacturing Build to Package 6 Manufacturing Operations 6 Manufacturing Project Defaults 9 MBTP 6 MBTP Reports 63 Modifications 47 T The Work Order Report creating 30 Twist Sequence 31 Types of Documents 5 W Wire List 1 End Terminator 72 Wire List End Terminator 75 Wire List by Coil 69 Work Order Report creating 17 Working Report creating 28 Printed for reference only HarnesSys volume 7 Manufacturing 82 This user guide is one of a set of user guides that make up Volume 7 of the HarnesSYS user documentation Below is description of the volumes of the HarnesSYS user documentation Volume 0 Getting Started Volume 1 Schematics Volume 2 Layout Drawing Volume 3 Wires Volume 4 Parts Volume 5 Integration Volume 6 Management and Configuration Control Volume 7 Manufacturing Volume 8 Technical Publications Volume 9 Retrofit Printed for reference only
47. imum distances between Braid Stops etc editing the jig and jig table jig table dimensions rotate bend symbols using the HarnesSYS 2D Routing Jig program integrating the MBTP document to produce Work Order report file making manual changes to manufacturing data not engineering design data producing other manufacturing reports The following figure illustrates the manufacturing process The upper section of the figure describes the engineering processes that must precede the manufacturing activities The HarnesSYS program used to perform each operation is printed in the background box of the operation Printed for reference only Introduction Schematic Diag Make Schematic Diagram Integrate Database Database Config Ctrl Sys Config Ctrl Sys Release Release Wire List Parts List Importing 3D Diagrams 2D Routing Jig Make 2D Layout Diagram Config Ctrl Sys Define jig Diagram Document Integrate Jig Diagram Config Ctrl Sys Config Ctrl Sys Engineering Build to Package Define Document Release jig Diagram Config Ctrl Sys Release 2D Layout Diagram Config Ctrl Sys Release
48. l appears sorted according to Coll No 1 twist sequence Each line of the report presents general information about a different coil see example below RELEASED DOCUMENT DATE 2006 12 03 page 2 1 COIL SUMMARY DOC NO DEH HBTP SNHLO34 1 REVISION New WIRING DEPARTMENT A TEAM Y BRANCH ITEM pin COIL CABLE BRADY SLV LETTER NUMBER NO COUNT COLOR CM 15 5 JUMPERS list Solder AA 34 1 1 11 13 AB 34 2 2 12 Summary Report Page Coil Summary report presents the following information Number 1 Coil Summary The type of manufacturing report lt 3 REV The revision letter of the selected MBTP document 5 WIRING Details describing the department to which the DEPARTMENT MBTP is assigned from Project Defaults Termination Indicator If the part described in the line is a Ist end terminator Ist Solder appears If it is a Partial connector Partial appears Otherwise 1 if 1t 1s a 2nd end terminator this field 1s blank 7 BRANCH LETTER The Branch Letter of the part This indicates the area of the Jig where the part should be placed ITEM NUMBER The part number of the part Ed COIL NO The coil number for the part 1 CABLE COUNT The number of cables connected to the part Cable 1 Printed for reference only HarnesSys volume 7 Manufacturing 66 NEED as a lone wire or a
49. lumel CLR The color of the wire s insulation as entered the wiring diagram If no color was entered in the wiring diagram and the wire 15 twisted appears The name of the shield the wire is in document Ss environment Not First Solder N appears for a first solder otherwise this field is blank Ferrule wire name 18 REV The revision of the selected MBTP document SEC PIN The pin of the TO connector SOLDER SEQ The soldering sequence of the wire 21 LENGTH The total cut length of the wire being the point to point length plus the length added for Brady tape and twisting in the units determined Project Defaults 22 WIRING DEPARTMENT Details describing the department to which the MBTP is assigned Printed for reference only HarnesSys volume 7 Manufacturing 12 The report 16 divided according to Ist end Note that each section has list of the parts it The main part 1 displayed first followed by the secondary parts Each part 15 described by the following fields 23 Description The description of the connector from Parts Specifications 24 Designator The designator of the connector The part number of the connector 26 Qty The quantity of the part described according to designator that is used in the assembly 27 C Angle The clocking angle of the connector from Parts Specifications Printed for reference only Chapter
50. nator report if both Ist and 2nd or just the 2nd was made The notes order is determined for the MBTP document using the Standard Notes option modify MBTP This operation assigns a sequence number to each note used in the MBTP Wire list and Parts list documents Hire List 2nd End TerminatorDOC AVI HBTP 12345 001 REV is VER HIRING DEPARTHENT 9999 HOTES 1 1 THIS IS THE FIRST LINE OF HOTE 1 THIS IS THE SECOND LINE OF NOTE 1 THIS IS THE THIRD LINE OF NOTE 1 8 THIS HOTE IS FOR PARTS THIS LINE COHTIUES PARTS 5 8 THIS HOTE IS ONLY FOR PART 10 THIS HOTE IS FOR ALL APPLICATIONS 1201 TESTING HUH 2 4 THIS HOTE IS FOR WIRES CONTINUATION HOTE 4 1 7 THIS HOTE BE USED FOR HIRES aon Standard Notes Printed for reference only HarnesSys volume 7 Manufacturing Hand Ringout The Hand Ringout report describes how to perform a ringout test for the bundle OPEN DOCUMENT E 602Y P AA 1 TS A dope aes WEM DW 1 1 poe Te Len XA s 2 7775 MEME CO Ah bc CM DATE 2001 03 18 d 2 HAND RINGOUT HH000000005A A Hand Ringout Report Page v Y SFX COLOR SPC P UM A A ee RE MEE 5 A A P MH A Each data page of a Hand Ringout report contains the following information
51. ng Brady Tape Denmmitions arenen a een 25 Creatine a Workina RODO u 26 EOF NI SACS 27 The Work Order Repo iced a ta 28 Banner Pages oss rigo Mn oem Lco 28 Dection TE TwISL Seque lee oue uui EUR DUE 20 section 2 List Tst End Solde eee sa sup 33 Sections LasEor 2nd End Soldepuu uuu u uu 36 Section 4 List of Wires Not Connected at Either End 39 Section 5 Wires Link the Following Connector 42 Chapter 5 Makine Modifications aces pua na Sk edu su e ed ua ren 45 Chapter 4 Manual Changes for ManufacturiIng 47 Sete PAC ONCIUOTS de ie nettes 49 Ony Jumpers ei si 50 TossetiPath COndIt615 tese aa ne 50 To Set 50 TosS rilol DBICoylii 222 0 ne nid 51 Te det Prom Connector Cong Ons sich uuu l 21 Jo Set 6C OINIGGIOr ia 52 Set From Col Number Conditions y uuu prster l par Shenae 52 Coll Number C OBGIUONS
52. nnector determined by the software or by the user These are the wires that cannot be attached to connectors at either end before assembling the bundle on the jig The following information 15 detailed for each wire this section no A sequential reference number for the wlre for this section of the report only FROM The From connector defined for the wire TO The To connector defined for the wire WIRE NAME The name number of the wire GA TY The gauge type of wire S1 S2 S3 The twist or shield family to which the wire belongs Printed for reference only HarnesSys volume 7 Manufacturing rer LIST HIHRES H O T vun cH a S E CO HHE CT T E I E H D no FROH TO HIRE GA TY 81 52 53 see 1 8 F000000001485 24 2 H0000000092A 24 3 BYP 109TB F0000000100H 24 on next 4 F0000000193B 24 B 5 F0000000103D 24 page 6 F0000000207 24 T 2G iG G0000000002A 24 8 109 P G0000000009E 24 9 GO000000010P 24 10 L0000000108G 18 AA 11 L0000000118C 24 12 10000000252 24 13 10000000264 22 14 100000002868 24 15 H0000000154E 22 16 000000155 24 17 2000000001285 18 36TB G0000000012B 24 19 G0000000013A 24 20 TG G00000000178B 24 21 L00000000695 24 22 L0000000070C 24 23 T TB 0000000212 24 B 002 24 143 0000000212 24 004 28 0
53. odified BTP document Stage 6 Update the definition of the MBTP document by selecting the new issue of the BTP document To do this select the document and then select Modify Document When this is done a special report detailing the differences between the new MBTP and the previous one is automatically produced Stage 7 Using the View MBTP option produce updated manufacturing reports After performing these operations you have a report detailing the changes generated when the MBTP document was updated Stage 6 above and updated manufacturing reports The Work Order file however has not been changed This allows you to continue using the previous Work Order report and incorporate the changes as you see fit If desired you can also integrate the updated MBTP document to produce an entirely new Work Order file which includes the changes made The following figure illustrates this process as an overlay over the engineering and manufacturing operations discussed earlier The operations to be performed to incorporate an engineering design change are printed in bold Printed for reference only HarnesSys volume 7 Manufacturing 46 2D Routing Jig Schematic Diag Modify Make 2D Schematic Layout Diagram Diagram Integrate Importing 3D Mo Diagrams Config Ctrl Sys Define Jig Diagram Database Database Document Integrate Jig Diagram Config Ctrl Sys
54. of changes you can make Further details on the screens and step by step instructions are given in the following Operating Instructions section Printed for reference only HarnesSys volume 7 Manufacturing 48 1 Select Modify from working space The Manufacturing Methods window appears MANUFACTURING METHODS COIL SUMMARY Y MBTP IZK 2003 Ne FROM TO DESIGNATOR PIN DESIGNATOR PIN COIL NODE COIL FROM TO WIRE BRADY TAPE SLEEVE LENGTH MANUF OOOOOOOOOOHO 522 2046 52 00260 52 amp 1P N3424 11 6P F042F 89 GND4 B002 11 s2P D024C 52 00260 52 D 1P N3424 6P F042F 11 897 Bo01B CO 841 818 0 SP E260 GND4 001 Re organize paths 50 From lt To Coil Number SP E260 111 sP ESO 111 521 1154 IC FRM 40815 Variable GLOBAL PATH_CURR_PART does not exist Record 171 Insert PE P gt E I 29 Printed for reference only 11009409303 Update display immediately Y N earch Wire bv Nam E 11100001000 N Manuf wire lengths in this path are not equal Chapter 4 Manual Changes for Manufacturing 49 Setting Path Conditions At t
55. ons To produce a Work Order file follow these steps 1 From the Working Space select the MBTP document and press the Integrate button The program displays the Integrate MBTP window Integrate MBTP select Operations Create Work Order Update Brady Tape Working Report The Integrate MBTP Window There are three options Create Work Order creates a Work Order file It is always available This 1s the standard type of integration The two additional buttons are only available after creating the Work Order file Update Brady Tape updates the Brady Tape definitions Working Report produces a Working Report that is described later in this chapter Printed for reference only HarnesSys volume 7 Manufacturing 16 Creating the Work Order Report 2 Click Create Work Order and press The integration process begins and an MBTP Integration window detailing the process 15 opened Example Integration x Work Order for JIG wires data The following CONNECTORS are of type GROUND 721 1 41641 ENTER gt to set GROUND CONNECTORS 27 SOLDER U t exit The following are REFERENCE CONNECTORS ENTER SLR to set REFERENCE CONNECTORS as 2 nd SOLDER to exit For set SPECIFIC CONNECTORS as 2 nd
56. re 1s in deter mined by the Wires program 13 TYPE The Type field of the wire Composed of Fam Type and Spec Type See the Integrate User Guide for details The type of wire according to specific work environment derived from the Wire Specifications library 16 LENGTH The total cut length of the wire being the point to point length plus the length added for Brady tape and twisting in the units determined in Project Defaults BRADY The color of the Brady tape defined for the coil 18 T E The Tetra Etch defined for the wire insulation etching for potting Can be manually changed for the wire via the Wires screen see Manual Changes for Manufacturing earlier in this manual 19 SLEEVE FROM The length of protective sleeving for the From end of the wire for non hook up wires Manually entered via the Wires screen see Manual Changes for Manufacturing earlier in this manual The length of protective sleeving for the From end of the wire for non hook up wires Manually entered via the Wires screen see Manual Changes for Manufacturing earlier in this manual 21 From and Termination Code field Bin code Lug m NN STRIP LEN F The bincode s Strip Length FERRULE COD The 2 character code describing the ferrule for the wire Manually entered via the Wires screen see Manual Changes for Manufacturing earlier in this manual FERRULE The ferrule length 1n inches or millimeters as defined in
57. should be added to the wire next Brady Ist Brady tape tape Brady Tape Colors The Brady colors that have already been defined are displayed in the window in this part of the section To define a new Brady color enter the code and description in the two boxes under the window and press the Add button To remove a defined Brady color click on it in the window and press the Remove button To change a color definition click on it and press the Remove button The definition is transferred to the boxes under the window Type over as desired and then press the Add Button Printed for reference only HarnesSys volume 7 Manufacturing 12 Braid Defaults 4 The right side of the Manufacturing Project Defaults screen enables you to define default minimum distances related to braids as described below Enter the default values as desired There are four General Defaults which describe Minimum Distances a Part Edge and Ferrule Area the distance between the part edge and the beginning of the ferrule area see C lt ferrule area gt gt part edge lt V b 2 Levels of Braid Stops the distance between the first and next braid stop see D c Last Braid Stop and Cable Code ID the minimum distance between the last braid stop and the cable code ID see E 1st level next level braid cable code braid ID part edge d Last Braid Stop and Breakout the minimum
58. t for 1 st 77 for 1 st 14 1 st nd END SOLDER 13M for 1 5 11M for 1 st Printed for reference only END END END END END END END END The integration process is performed and detailed in the message window SOLDER SOLDER SOLDER SOLDER SOLDER SOLDER SOLDER SOLDER 22 Chapter 2 Integrating an MBTP Package 23 End of Integration Process 12 13 14 The integration process is detailed in the message window See Work order on file usr users disk23 wolgro harness CHK private 25w MBTP 1101 888 work order wrk ENTER C FOR COMMIT S TO STOP D B Updating Validate the Work order file Press C Commit and Enter to update the databases EMI of OPERATION ERERTE Process terminated To close window type lt C gt Press Enter to close the message window Note In your private directory in addition to the Work Order file you will find a Log file detailing errors encountered during the integration process Printed for reference only HarnesSys volume 7 Manufacturing Printed for reference only 24 Chapter 2 Integrating an MBTP Package 25 Updating Brady Tape Definitions To update the Brady Tape definitions after creating the Work order file choose Update Brady Tape in the Integrate MBTP window and press OK Integrate X select Operations Create Work Order Update Br
59. t as 2nd end SET CONNECTOR 109YP to 2 nd END SOLDER SET CONNECTOR 82TB to 2 nd END SOLDER as a result of SET CONNECTOR 15TB to 2 nd END SOLDER your 1st end SET CONNECTOR 2G to 2 nd END SOLDER To znad END SOLDER selection SET CONNECTOR 3XYP to 2 END SOLDER SET CONNECTOR 81TB to 2 nd END SOLDER SET CONNECTOR 143H to 2 nd END SOLDER SET CONNECTOR 12M to 2 nd END SOLDER SET CONNECTOR 5M to 2 nd END SOLDER The remaining connectors those not yet designated as starting or ending connectors are displayed to allow you to select another starting connector Printed for reference only HarnesSys volume 7 Manufacturing 20 1 6 1 0 151 NUMBER_OF_WIRES 2 2 CONNECTOR_NAME 109TB DIAMETER 0 153 NUMBER_OF_WIRES 5 connectors 3 CONNECTOR_NAME 8G DIAMETER 0 197 NUMBER_OF_WIRES 9 not yet set 4 CONNECTOR_NAME 2 2 0 178 NUMBER_OF_WIRES 2 as ist or 5 CONNECTOR NAME 2 DIAMETER 0 178 NUMBER_OF_WIRES 2 6 CONNECTOR_NAME 242H DIAMETER 0 140 NUMBER_OF_WIRES 3 2nd end 7 7 DIAMETER 0 182 NUMBER_OF_WIRES 3 connectors 8 _ 1 478 DIAMETER 0 199 NUMBER_OF_WIRES 5 9 CONNECTOR 6 DIAMETER 0 235 NUMBER_OF_WIRES 7 10 13 DIAMETER 0 132 NUMBER_OF_WIRES 2 11 CONNECTOR_NAME 11M DIAMET
60. uration gt Release gt Document from the Working Space Menu The Release Document Window appears Release Select Document Documents DEMMBTP11400 0002 DEHHN BTP 11336 1001 DEHPART REP 2 DEHPL 22020 0001 DEHPL 99090 2020 Effectivity Filter Selection Select Document for Release Window 2 Select your required document using lt 1 gt and Click OK Printed for reference only HarnesSys volume 7 Manufacturing The Document 5 Release Window appears for confirmation showing the document s parameters Release Document DEMMETP 11400 0002 Document Name DEMMPBTP11400 0002 Sheet 1 of 1 Application M BUILD TO PACK Base number 11400 Effectivities Dash number 0002 030 0040 Prefix Suffix Category Title Designer Security UNCLASSIFIED Doc Status OPENED Doc Current Issue B Doc Status date 1998 04 09 13 23 51 Doc Released Revision Letters A Document last change date 1998 04 09 13 23 51 Document s definition last change date 1998 04 09 13 23 51 The Release Confirm Window e To confirm click OK The confirmation message appears Harnessys Information 4 Click OK to exit Printed for reference only 80 Index Index 2 2D Routing Diagrams 5 B Banner Page 30 65 Brady Tape updating 27 Brady Tape Defaults 11 Braid Defaults 12 Build to Package BTP 5 C Changing Designator Data 59 Changing Pat
61. y Selecting Starting Connectors 6 A list list of connectors with the number of wires connected to each and their combined diameter prompt for starting connector number of connectors and a prompt are displayed 1 _ 12 142 NUMBER OF_WIRES 1 2 CONNECTOR_NAME 61TB DIAMETER 0 151 NUMBER_ OF_WIRES 2 3 CONNECTOR_NAME 54P DIAMETER 0 376 NUMBER OF_WIRES 26 23 lt 6 DIAMETER 0 235 NUMBER_ OF_WIRES 24 CONNECTOR_NAME 1 3 r DIAMETER 0 132 NUMBER_OF_WIRES 2 25 CONNECTORZNAMEZ11H r 109 NUMBER OF_WIRES 1 SELECT CONNECTOR NUMBER lt CR gt to program default or Q to exit response to the SELECT CONNECTOR NUMBER prompt To continue without selecting starting connector automatic program selection press Enter You go automatically to Step 9 To quit without making Work Order report press and Enter Enter the number of connector you want to set as a starting first end connector and press Enter The program now designates the other connectors on the same path as ending terminators 1 second end connectors This process is displayed as in the example below SELECT CONNECTOR NUMBER i CR to program default or Q to exit 2 13 SET CONNECTOR 7G to 2 nd END SOLDER SET CONNECTOR to 2 nd END SOLDER the connectors SET CONNECTOR 78TB to 2 nd END SOLDER se

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