TP1 –

DESIGN RULES FOR THE AUTOMATION OF THE WIRING HARNESS

Automation-friendly wire harness design

In subproject 1 (TP1), design rules are being developed that lead to automation-friendly designs of wire harnesses. Important indicators are the number of different components, the complexity of the manufacturing processes, and the actual structure of the wire harness. Both are formulated, hard rules (compliance with which can be evaluated digitally) and recommendations of a less binding nature. The design rules are standardized in DIN 72036. An outlook on possible advances in machinery and equipment is provided.

Initial situation and motivation

The manufacturing process of a wiring harness passes through various disciplines, from development to assembly in the vehicle. The value creation itself is optimized in each company for the respective area of activity. A holistic approach to the value chain is therefore an essential factor in enabling more efficient production of the wire harness. The various motivations and experiences are to be incorporated into the early stages of wiring harness development through close coordination between the individual companies. A designated goal is to project the impact of technology decisions onto the wiring harness in early concept and design phases. As a result, automation obstacles can be avoided, and cost-effective automation can be enabled. Cooperation in standardization can achieve a global optimum for value creation and automation in the wire harness industry.

Current areas of work

The main focus of work in TP1 is on developing further design rules and optimizing the application of DIN 72036. Feedback from companies in the wire harness industry on the standard will be taken on board and prepared for the upcoming update of DIN 72036 in 2025. A new task is the coordination of design rules across several application levels – common design rules for low-voltage, high-voltage and high-frequency wire harnesses.

Outlook

TP1 aims to raise awareness of the highly automated production of wire harnesses. The existing design rules in the low-voltage sector will be expanded, deepened and optimized. In addition, topics such as the assembly of partial wire harnesses and purchased parts are included in the consideration.