The document discusses strategies for modifying harness assemblies through planned "surgery" rather than emergency "triage". It provides examples of common changes like synchronizing logical references, replacing connector models, rerouting pathways, splitting wires, adjusting bundles, and considerations for downstream deliverables. The key is to apply the best solution through diagnosis, use trained resources with advanced skills, and precisely treat issues while avoiding shortcuts that could cause downstream problems.

1. How to Perform Surgery and
not Triage when Modifying your
Harness Assembly
Cassandra Kemp, CeDeL Solutions LLC
Pete Pickett II, Mercury Mercruiser

2. Triage vs. Surgery
• Triage
– Emergency situation/ Unplanned Event
– Limited time to assess and prioritize the problem
– Shortcuts/Short term
– Not much skill involved
– Not considering downstream issues
• Surgery
– Planned Event/Timely
– Applying the best solution through diagnosis
– Trained resource with advanced skills
– Precise treatment manual or instrumental treatment
– Lifesaving (Time saving)

3. Common Changes –
Modifying a Harness
• Synchronizing Logical
References
• Replacing connector models
• Rerouting/Redefining
pathways
• Splitting a wire/cable
• Adjusting Bundles
• Considerations to
Downstream Deliverables
• RESOLVE MODE!
Understanding failures

4. Case# 1: Synchronizing Logical References
• Symptom
– Connectivity and/or parameters have changed in the 2D
schematic
• Diagnosis
– Update logical references from an modified/new RSD diagram
• Treatment
– Import new XML and Logical Ref > Compare (WAS-IS)
– Update property information Logical Reference>Update
– Automatic changes (Requires Regeneration Only)
• Wire names, spool changes*, component properties
– Manual Changes (Requires action)
• Create features, Delete segments, manual/autoroute,
Designate

5. Spool Change
Connectivity Change
Wire Name Change
Component Parameter
Ref Des Change

6. Case #2: Replacing A Connector Model
• Symptom
– Connector model has changed which affects routed segments
• Diagnosis
– Replace the connector and redefine routing references
• Treatment
– Automatic replacement
• Connector>Replace> select family table or interchange group
– Manual replacement
• Hide original connector and assemble new connector
• Reroute locations references to new connector
• Delete routed portion to the ENTRY csys
• Suppress original connector to detect children then delete if none
• Designate and Update connector and manually/auto route
• Tip: Family table connectors are the easiest to replace

7. Case 2 Demo

8. Reducing your Risk Factors
Component Creation
• Datum Axis off end of each component
on a sketched datum curve.
• Use Component Interfaces for
connectors. Axis as one constraint if
necessary.
• For terminals and seals, consider making
the assemblies flexible or use family
tables
• Consider UDF features in the skeleton
reference in space

9. Case #3: Rerouting a pathway
• Symptom
– Change to surrounding environment affects harness pathway
• Diagnosis
– Replace references using “Reroute”
• Treatment
– Location>Reroute; either
• Reroute Feature – recall and reselection of references (single feature)
or
• Replace Reference – from one entity to another (single feature or all
children of that reference)
• Tip: When Rerouting locations using the same reference, it is easier to
Replace Reference > All Children

10. Case #4: Redefining a pathway
• Symptom
– Diverging pathways need to be consolidated into one pathway
• Diagnosis
• Redefine locations on the pathway
• Treatment
– Determine the type of location created Info > Location
– Select the location and redefine to an existing location
• Location> Redefine> Location
– Repeat for each location until the paths converge
• Tip: Use Location>Reroute when you are only replacing
references and use Location>Redefine to change the type of
location as well as the references

11. Case 3 and 4 Demo

12. Case 5: Splitting a wire/cable
• Symptom
– Diagram changes require a routed wire to be split into two wires
and connected to an inline component.
• Diagnosis
– Use Split functionality to split wire and route to inline component
• Treatment
– Under Modify > Split cables > Select the wire > Enter names for
the segments
– Insert new connector > AutoDesignate and Logical Ref > Update
– Autoroute the wires to the connector
Tip: If you name the wire segments incorrectly, then use Modify >
Parameters to correct the names

13. Case 5 Demo

14. Case #6: Adjusting Bundles
• Symptom
– Wires/Cable needs to be removed from an existing bundle and
routed into another bundle
• Diagnosis
– Remove wires from bundle using Mod Bundle Functionality
• Treatment
– Modify > Mod Bundle > Select bundle > Extract cable > Select
wire/cable to remove from the pick list
– Modify > Mod Bundle > Select bundle > Add cable > Select
wire/cable to add from the pick list
• Tip: When removing wires from a bundle, they may not follow
the same orientation prior to bundling

15. Case #7: Adjusting Bundles
• Symptom
– Bundle needs to be removed but all the contents (wires/cables)
need to remain routed
• Diagnosis
– Delete bundle but not bundle contents
• Treatment
– May consider changing Tubing Bundle Sheath to Shrink Bundle
Sheath
– Feature > Delete > Del Feature > Select bundle id from Model tree
or Use Find
• Tip: If you select the bundle from the model then make sure to
select the Cable: Bundle and not Seg:Cable:Bundle to
automatically extract the wires/cables from the bundle

16. Case 6 and 7 Demo

17. Consideration to Downstream Deliverables
The flatten harness and flatten harness drawing are directly
related to the 3D harness part, therefore:
• Do not flatten the network.
– config option: fan_with_network no (default value is set to yes)
• Always create a 3D note on the first set start point
• Changing parameters, references or adding location does not
negatively affect the flattened harness
• Use Info > Flat Status to detect any changes
• Deleting and routing new segments will require reflattening and
recreation of created or shown dimensions
• Tip: Redefining rather than removing will minimize reflattening

18. Resolve Mode for Harness
• What are common problems?
• Missing References
• Minimum Bend Radius
• What happen when a harness feature fails
– Pro/E launches Resolve Mode
– Resolve by Undo only works for dimensional changes
– Problem must be resolved before a Save
• Cont’d…

19. Resolve Mode for Harness (cont’d)
• Troubleshooting the model / Interpreting the symptoms
– Read the resolve dialog box
– Always investigate to examine any changes in model and view
parent/child references
– Quick Fix vs. Fix Model
• Tip: Avoid Resolve model and harness failure by using robust
references and routing with the material in mind

20. Resolve Mode – Exceed Min Bend Radius
• Investigate the change:
– Investigate > Fail Geom > Item Info
• Resolve the problem:
– Fix Model > Application > Cabling > Spools > Modify the min
bend radius > Regenerate
– Fix Model > Application > Cabling > Location > Move

21. Resolve Mode – Missing References
• Investigate the change:
– Investigate > Show Ref
• Resolve the problem:
– Quick Fix > Reroute > Missing Ref>All children
• Tip: WF 4.0 Freezes failed locations

22. Prognosis
• You are on your way to a Road
of Recovery
• Welcome design changes for
your harnesses
• Practice Precision
• Save Time! Resolve don’t
Recreate
• Keep up with the latest
datecodes for software fixes
• Happy Routing!

23. Questions & Answers

25. • Resolve mode
– Common problems – Missing reference, cannot make minimum bend
radius
– Regenerate for failure
– Reading and exploring the problem using the resolve mode interfaces –
Dialog box-Missing References
– Resolve issue – Investigate > Show Ref
– Quick Fix > Reroute > Missing Ref > All Children
– Mapkey import changes – Resolve Mode- Min bend radius
– Fix Model > Application > Cabling > Spools > Modify the min bend radius
> Regenerate
– Fix Model > Application > Cabling > Location > Move
Downstream Deliverables Demo