One of the biggest benefits that using SOLIDWORKS Electrical Schematic and SOLIDWORKS Electrical 3D brings us is the ability to get a single cohesive view of my electro-mechanical assembly. As a design team, we can showcase our designs from a 2D schematic perspective as well as a fully modeled and routed 3D assembly. Without SOLIDWORKS Electrical, this can be challenging when working with complex cables with multiple conductors and connectors to keep track of. Fortunately, the SOLIDWORKS Electrical Suite has integrated tools to help manage even the most complex cables.
Creating Connectors and Assigning Manufacturer Parts
The process for creating and assigning connectors in the Electrical Project is largely the same as any other component: select the symbol, add the base part, and define any accessory/auxiliary parts. However, the major difference with connectors is the ability to utilize Dynamic Connector Symbols (thanks to Electrical Schematic Professional). After selecting our base connector from the library a new manager appears that allows for specific terminals for the connector to be inserted. What this means is that selecting all terminals will give a full connector symbol while selecting on a few will dynamically generate a smaller, more compact symbol.
Just like any other symbol in SOLIDWORKS Electrical, attributes can be automatically updated from the component selection. Additionally, the auxiliary components can be added to have a more complete bill of materials that includes both the connector housing as well as any specific terminal/contacts we want to define. Ultimately, the contacts will have no bearing on the final 3D Assembly but give us better design intent and easier ordering.
Defining Components as a Harness Assembly
There are a lot of objects that get tracked at a higher level in the Electrical Project such as terminal strips, PLCS, and locations that allow for easier organization and traceability. Cable harnesses are no different and using the Harness Management tool allows for a bird’s eye view of every wire, cable, and component that goes into a cable harness. Additional harnesses can be defined and any unassociated components or wires can be bundled up to be added to a cable harness assembly.
Routing the Harness in SOLIDWORKS
The real magic occurs when SOLIDWORKS Electrical Schematic combines with SOLIDWORKS Electrical 3D. Like any other Electrical Assembly, the filters can be used to shorten the list of components to just those that need to be added (removing any of the accessory/auxiliary components as well). From here, the parts and symbols library takes control and automatically pulls the correct 3D model for a component based on the manufacturer part selection. With the help of mate references, the connectors can easily snap into place on the mating female connector for the assembly. Cable harnesses can be routed manually with each branch being specific with built-in routing tools or by using auto-routing. When auto-routing, it can be helpful to use the “Draw Graph” command to preview where the route will go to ensure everything is connected and going where it should.
Because this is now a SOLIDWORKS Routing Sub-Assembly the normal evaluation tools such as interference detection can be used. If changes need to be made, it is easy to do so with the built-in routing tools to adjust or fully reroute sections to make sure the cable harness is going exactly where we would expect. Notice how fanouts are automatically generated for each connector and the bundle thickness adjusts based on the number of conductors running through it. A bonus is that a cross-section can be generated for the cable to see all the conductors running and the space they take up.
Creating a Manufacturing Drawing
Opening the routing sub-assembly on its own empowers the user to see all the twists and turns the cable harness takes without obscuring the view with the rest of the mechanical assembly. More importantly, the harness can be flattened to see the true size of everything laid out. There are options to only use straight segments, specify component orientation, and further adjust the flattened harness to rotate, straighten, or bend segments. With everything laid out appropriately, a drawing can be created. The drawing can use a standard drawing template, as well as templates for Electrical Bills of Materials, Cut Lists, and Connector Tables. The tables will be filled in with information being pulled from the Routing Sub-Assembly. This means that the To/From lists and lengths for wires will be accurate as per the Electrical Schematic and Electrical 3D Routes clearing up any ambiguity between design and reality.
Whether you are looking to create better cable harness BOMs or have more accurate manufacturing drawings, the SOLIDWORKS Electrical Suite might be the tool for you. With a lot of time-saving and error-reducing tools, you will be able to experience a more efficient electrical design process. There are a few different options to get started with SOLIDWORKS Electrical so reach out to your local account manager or Contact Us to start your electrical journey today!
