This document discusses harness design using PTC CREO. It summarizes Cedric Kron's experience with harness design for various satellite and medical device companies. It then outlines the design process using Pro/Engineer/CREO, including preparing top level assemblies, creating harness parts and networks, importing wire lists, running wires, and preparing drawings with various views and annotations. Previous space programs involving satellites for communications, remote sensing, and resupply to the International Space Station are also summarized.

1. Harness Design with PTC CREO
by
Cedric Kron

2. Introduction
Harness Design Experience
Previous Satellite/Spacecraft Programs
Pro/Engineer/CREO Design Process
Conclusion

3. Harness Design Summary
Harness Design for...

Ortho Clinical Diagnostics
(Medical Devices – Blood Analyzers)

DRS Technologies
(Defense Contractor)

Orbital Sciences Corporation
(Aerospace/Satellites - communication)

ITT Industries – Space Systems Division
(Aerospace/Satellites – remote sensing)

4. Previous Space Programs –
Satellites (Hylas II)
Coverage
Europe
Middle East
Africa
Mission Description
The HYLAS 2 satellite carries 24 active
Ka-band user beams and six gateway
beams, and produces approximately 5.0
kilowatts of payload electrical
power. The Ka-band spot beams provide
two-way communications services
to facilitate high-speed delivery of data to
end-user applications such as
corporate networking, broadband
Internet access, business continuity
services and video distribution. Using the
HYLAS 2 spacecraft, Avanti provides its
data and video services to Eastern and
Southern Africa, Eastern Europe and
the Middle East. In addition, the
spacecraft is equipped with a steerable
spot beam, also operating at Ka-band,
which provides coverage anywhere on
Earth that is visible to the satellite.
Source:www.orbitalatk.com
Photo:http://space.skyrocket.de

5. Previous Space Programs –
Satellites (Star One - C3)
Coverage
Brazil
The Andes
South
America
Mission Description
The Star One C3 satellite, manufactured
for Star One, carries a hybrid payload.
The satellite's C-band payload serves
South America. The Ku-band payload
serves Brazil and other areas of South
America.
Source:www.orbitalatk.com
Photo:http://www.starone.com.br

6. Previous Space Programs –
Satellites (Mexsat–Bicentenario - 3)
Coverage
Mexico
SurroundingWaters
Mission Description
Orbital ATK was selected by the Boeing Company to
provide the Fixed Satellite
Services (FSS) segment of the Mexsat satellite system for
the Federal Government of Mexico. The Mexsat system is a
three satellite system consisting of two Mobile Satellite
Services (MSS) spacecraft designed and built by Boeing
(Mexsat Centenario and Mexsat Morelos 3) and one FSS
satellite, Mexsat Bicentenario, designed and built by Orbital
ATK.
Mexsat Bicentenario is based on Orbital ATK’s GEOStar™-
2 platform, generates approximately 3.5 kilowatts of
payload power and carries 12 active extended Ku-band and
12 active extended C-band transponders. The spacecraft
provides communications services to Mexico and its
surrounding waters from the 114.9 degrees West Longitude
orbital slot. In addition to the Mexsat Bicentenario
spacecraft, Orbital ATK also provided the FSS ground
segment, including the satellite command and control
ground equipment and software as well as training and
operational documentation.
Source:www.orbitalatk.com
Photo:www.space.skyrocket.de

7. Previous Space Programs –
Satellites (SES - 8)
Coverage
South Asia
Indo-China
Mission Description
SES-8, a hybrid Ku- and Ka-band
spacecraft, is the sixth GEOStar™-2
satellite ordered by SES S.A. The satellite
is based on Orbital ATK’s Enhanced
GEOStar-2 bus, and carries 24 active Ku-
band transponders of 36 or 54 Mhz
capacity switchable amongst 33 channels
and two beams. Certain channels in
each beam are cross-strapped to multiple
frequency bands, enabling flexibility
for new services. In addition, the spacecraft
features a Ka-band payload.
The spacecraft generates approximately
five kilowatts of payload power and
features two 2.5 x 2.7 meter super elliptical
deployable reflectors and a 1.45
meter fixed, deck-mounted antenna.
Source:www.orbitalatk.com
Photo:www.spacenews.com

8. Previous Space Programs –
Satellites (Thaicom - 6)
Coverage
Thailand
Laos
Cambodia
Myanmar
Southeast Asia and Africa
Mission Description
Orbital ATK was selected by Thaicom PLC to
build their sixth satellite, Thaicom
6. The Thaicom 6 satellite design is based on
Orbital ATK’s highly successful,
flight-proven, GEOStar-2™ satellite platform,
and was manufactured and tested at Orbital
ATK’s state-of-the-art manufacturing facility in
Dulles, Virginia.
Thaicom 6 carries a hybrid Ku- and C-band
payload operates on approximately
3.5 kilowatts of payload power. The Ku-band
payload is comprised of eight
active transponders (9 x 36 - MHz
Transponder Equivalent) providing services to
Thailand, Laos, Cambodia, and Myanmar. The
C-band payload features 12 active C-band
transponders providing services via a regional
beam to Southeast Asia and six active C-band
transponders (12 x 36 - MHz TPE) providing
services to Africa..
Source:www.orbitalatk.com
Photo:www.spaceflight101.com

9. Previous Space Programs –
Resupply to ISS
(International Space Station)
Photo:http://spacenews.com

10. Previous Space Programs –
Resupply to ISS
(International Space Station)
Overview
Orbital ATK developed the Cygnus advanced maneuvering spacecraft to
demonstrate cargo delivery services under a NASA Commercial Orbital Transportation
Services (COTS) Space Act Agreement. Orbital ATK uses
Cygnus to perform ISS resupply flights under the Commercial Resupply Service (CRS)
contract. Orbital ATK is under contract to conduct 10 missions to deliver approximately
28,700 kilograms of cargo to the ISS. The first of these was
successfully completed in early 2014.
The Cygnus system is a low-risk design incorporating elements drawn from
Orbital ATK and its partners’ existing, flight-proven spacecraft technologies. Cygnus
consists of a common service module and a pressurized cargo module. Cygnus is
used to carry crew supplies, spare equipment and scientific experiments to the ISS.
The service module incorporates avionics systems from Orbital ATK’s flight-proven
LEOStar™ and GEOStar™ satellite product lines plus propulsion and power systems from
our GEOStar communications satellites.
The pressurized cargo module is based on the Multi-Purpose Logistics Module
(MPLM), developed by Thales Alenia Space for NASA.
Source:www.orbitalatk.com

11. Preliminary Information - Inputs
Excel Speadsheet

Connectors

Families/Types

D-Shell

Circular

Locations

Wire List

12. Preparation
Top Level Assembly with Pro-E/CREO

Activate Assembly

Create Assembly (fix)

Assemble Required Items (fix)

Assemble Required Connectors/Splices (fix)

Connector Entry Ports

Place Harness Tie Bases

13. Network (path)
Create Harness Part

Place Network

Use Direction

Along Axis

Along Edge

Add Locations (for
Branches)

Min. Bend Radius

14. Wires
Import Wire List
Designate
• Connectors
• Splices
Run Wires
Troubleshoot

15. Drawing Preparation
Create Views

Projection

Front

Left & Right

Cross-Sectional

Cut Away Portion

Inside View

16. Drawing
Borders
Notes
Views
Call Out Bubbles

17. Conclusion
Harness Design Experience
Sample Programs
Pro/Engineer/CREO Design Process
Questions and Answers