TP1 -

TP1 - Design guidelines for low-voltage wiring harnesses

Sub-project 1 (SP1) is dedicated to the development and standardization of design guidelines that enable the automation-compatible design of low-voltage wiring harnesses. The aim is to use structured specifications to create a technical basis that can significantly reduce complexity in design and production - a key lever for automation in wiring harness production.

The focus here is on three key influencing factors:

• the variety and selection of components used,
• the complexity of the manufacturing processes,
• as well as the structural organization and demeshing of the wire harness.

The design guidelines developed in SP1 distinguish between binding rules and non-binding recommendations. While the rules are clearly verifiable and can be automatically evaluated in digital tools, recommendations are intended to provide guidance without triggering specific implementation obligations. Both types are systematically incorporated into DIN 72036, where they form the normative framework for LV line sets.

Despite the increasing importance of high-voltage and high-frequency systems, low-voltage wiring harnesses continue to make up the largest part of a vehicle's wiring system. TP1 therefore has a central role within the SILS - not only because it shapes the standard for LV wiring harnesses, but also because it represents a reference for other application levels. Several of the design guidelines developed are being tested for transferability in SP4 (HV) and SP5 (HF) and further developed there.

A significant advance in standard version 2 was the introduction of the so-called Degree of Design for Automation (DDA). This key figure allows an objective assessment of the automation-friendliness of a wiring harness design at an early stage of development. This creates a feedback loop between design and production that enables both transparency and targeted optimization.

In addition, members of TP1 are actively involved in the Processes task force, which is developing a consistent digital process description within wire harness production. TP1 is providing key input for version 3 of the standard, including

• the standardized modelling of modular wiring harnesses,
• the definition of rules for joining and separating partial scopes,
• as well as the systematic description and integration of cable protection and holder part applications.

The topic of meshing and the definition of potential target values for complex line sets are also currently being worked on. The aim is to quantify complexity and derive recommendations for structuring.

TP1 creates a viable core for DIN 72036 - a toolbox for developers and manufacturers alike that not only provides technical guidelines, but also helps to turn the automation of vehicle electrical systems from principle into industrial practice.