TP1 -

DESIGN GUIDELINES FOR THE AUTOMATION OF THE WIRING HARNESS

Automation-friendly Wire Harness

In sub-project 1 (TP1), design guidelines are developed that lead to automation-compatible designs of wire harnesses. Important indicators here are the number of different components, the complexity of the processing procedures and the actual structure of the wire harness. Hard rules are formulated, compliance with which can be evaluated digitally, as well as recommendations of a less binding nature. The design guidelines are standardized in DIN 72036. An outlook on possible advances in machines and systems 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 key factor in enabling more efficient production of the wiring harness is therefore a holistic approach to the value chain. The various motivations and experiences are to be incorporated into the early stages of wire harness development through close coordination between the individual companies. A designated goal is to project the effects of technology decisions onto the Wire Harness in early concept phases. In this way, automation obstacles can be avoided and economical automation made possible. Cooperation in standardization can achieve a global optimum for value creation and automation in the wire harness industry.

Current focus of work

The main focus of work in SP1 is the development of further design guidelines and the optimization of the application of DIN 72036. In addition, gaps in the optimization of production automation are identified with the help of a systematic linking of components and production processes, which are specifically closed with new design guidelines.

Feedback from companies in the wiring harness industry on the standard will be recorded and prepared for the upcoming update of DIN 72036 in 2025. An important goal here is to improve applicability in practice.

A new task is the coordination of design guidelines across several application levels - common design guidelines for low-voltage, high-voltage and high-frequency wiring harnesses.

Outlook

TP1 aims to raise awareness of the highly automated production of wiring harnesses. The existing design guidelines in the area of low-voltage will be expanded, deepened and optimized. Furthermore, topics such as the assembly of partial wire harnesses and purchased parts will be included in the analysis.