Wiring

Composite

Wiring Synthesis

Composite Wiring Synthesis (CWS) is available only if you have the full Capital Systems Integrator license (not the Capital Systems Integrator Fundamentals license). It is of most value in projects containing complex topologies with significant option content as it enables you to generate harness levels and wiring information automatically as part of the Capital generative flow. It automates the steps necessary to synthesize wiring for all of the harness levels for each harness in the vehicle and thereby synthesize wiring for each possible vehicle configuration.

It considers physical harness levels and assigns wiring to physical levels.

Figure 178: Composite Wiring Synthesis Overview

CWS and Harness Level Generation

For each harness in the electrical system, options that drive complexity for that harness are identified and associated with the harness. Harness Levels are defined to support various combinations of options for a harness. The following is a simple explanation using a car as the example for simplicity:

Every car has an ‘Instrument Panel Harness’ that sends signals to the various options available (for example, CD player, radio, steering column, air conditioning, and so on). Each harness level has a different combination of these options: one model may have the CD player another only the radio option while both may have air conditioning.

Obviously, several harness may connect to the various options; for example, the air conditioning option could be associated with the ‘Engine Harness’ as it supplies the necessary power.

The more options and option combinations that exist, the more complex the generation of harness levels is, therefore you may want to use CWS to automate the generation of harness levels (taking into account option definitions and wire routing requirements).

Caution

Modular wiring synthesis is run in the background in order to promote options to harnesses and generate harness levels. If modular wiring synthesis fails to complete, this could lead to incorrect option promotion and incorrect harness level generation. It is therefore recommended to run modular wiring synthesis as a separate step before running composite wiring synthesis in order to correct any potential problems with routing and option promotion before generating levels.

It is not compulsory to use CWS to generate harness levels. You can define them manually or import pre-defined harness levels if desired. If this is done, then only the ‘wiring synthesis’ and ‘combine identical harness’ steps are necessary when you run CWS.

The ‘wiring synthesis’ step requires that Harness Levels exist in order that the system can generate the wires for each harness within those levels. At a basic level, if no options exist, then just one harness level exists for each harness.

When options are introduced, you can generate or define several harness levels depending on the required combination of options.

In the example below, no options exist, therefore only one harness level is generated.

Figure 179: Define Harness Levels Dialog Box with One Level

In the next example, two options exist, therefore you must define or generate a harness level to reflect each possible combination of these two options:

Figure 180: Define Harness Levels Dialog Box with Multiple Levels

See Harness Level for more information about defining/generating harness levels and associated options.

CWS and Wiring Generation

Once harness levels exist, and options assigned, CWS can define and route the wires for the individual harness levels. When doing this, the system routes the logical signals and generates the required wires, splices and multi-terms. It determines the impact of optional devices and connections on the complexity of the harness system. Options and their relationships as well as additional combinational constraints described in the vehicle model(s) are used to derive the content of the max complexity harness for each of the harnesses defined in the topology. Wiring is then synthesized for each max complexity vehicle configuration.

Depopulated harnesses are then defined by removing options and associated wiring from the max complexity harnesses and synthesizing any new wiring required.

The resultant output from CWS is a fully defined set of harness levels and associated wiring which support all possible buildable system combinations. See Examples of Composite Data.

If you have added Wire Part Specification constraints and Terminal Type Specification constraints to objects, the system uses these to add properties to the wires that it creates. When creating splices, the system takes into account any set constraints or rules.

See Wire Routing Constraints Strategy andWire Synthesis Constraints Strategy for details of other constraints that are taken into account by wiring synthesis.

To summarize, CWS has the following prerequisites:

At least one vehicle model is defined. See Defining Models in a Basic Plan.
Options and option relationships are defined in Capital Project Manager or Capital Systems Integrator (inclusive/exclusive relationships and variants). See Option for more information.
All optional devices and connections are option tagged in the functional Capital Logic Designer diagrams and placed in slots in Capital Systems Integrator. See Assigning an Option Expression to an Object and Placement of a Device or Ground Device in a Slot for more information.
The system topology is defined including harness boundaries (inlines) and equipment positions (slots).
Allowable combinations of options are defined in the vehicle model(s). See Defining Models in a Basic Plan.
Constraints are added to topology objects as required. See Creating a Strategy for Constraint Definition in Capital Systems Integrator.

Once these prerequisites are met, you can use the Wiring Synthesis Dialog Box to choose particular synthesis steps that you want the system to perform or choose all of the steps at once. You can run all steps more than once and synthesis is incremental. There is no need to delete existing wiring after design changes are made and before running synthesis steps because the steps add new wiring as required and remove existing wiring that is not longer required. The individual steps for composite wiring synthesis are listed if you click Custom Settings.

If you click one of the buttons at the top of the dialog box, particular steps are chosen automatically. These options allow you to break the process for composite wiring synthesis so that you can specify giveaway options and thereby reduce the number of harness levels that are generated in the overall process.

Reporting on CWS Results

After the wiring is synthesized, you can generate basic reports from the Platform menu. You can create reports for bundle contents, multicore wire lists and a component bill of material. You can generate more detailed reports for options, harness levels and connectivity information. See Reports for more information.

You can edit the topological layout after wiring is synthesized and you can re-route the signals.

Parent Topic:

Wiring