Project examples and videos

 

Project Volvo: Comparison of variations in length and attachment

In this video you can see the comparison of two variations: One hose is attached by a flexible hose routing while the other one is only fastened at its ending points.

The task in this project with Volvo was to find the best length for the supply cables and hoses of a truck cab to resist the stresses while tilting the driver’s cabin in order to carry out maintenance and repair work. For this purpose, the CAD-model of the whole vehicle was loaded into IPS Cable Simulation: The hydraulic hose was automatically generated to be flexible on the basis of the defined connection points and the kinematic movements were displayed. The hose’s length was varied and the current strain was displayed by the software in real time. In this way the optimal length and installation position was determined. Furthermore, material strain and the need for construction space could be reduced significantly. By using IPS Cable Simulation the optimal route with places for clips and hose routings was found.

 

Project Saab: Determination of the required cable over-length for the assembly of an infotainment system

The installation of a car radio is usually one of the last steps of a car’s assembly. This is why difficulties related to the reduced installation space often occur. To guarantee a successful installation of the radio, the wires have to be longer than they would need to be for its proper use. Nevertheless, this overlength needed for the assembly increases the risk of collisions for the wires. There is a higher probability for self-contact and contact to other objects. In addition, there is a risk of buckling and damage in the installation phase. To minimize these risks we have determined the ideal lengths for the cables with the help of IPS Cable Simulation.

 

Project Audi: Damage analysis and optimization of the hose grommet at the tailgate

Due to different technical concepts of tailgates and their connection to the passenger compartment, no standard approach exists for laying the wiring harness in this part of the car. Until now the design was not based on simulation data. As a result, solutions were implemented which often led to malfunctions after the experimental phase, like in the present case: even though the hose grommet had been correctly installed, the wiring harness showed damage.

First, the process of opening and closing the tailgate was analyzed with the help of IPS Cable Simulation. By this means the most severely stressed section of the hose could be found. After that, the hose length was varied and an incorrect installation with misaligned hose by 180° was simulated. As a result it was found that an incorrect installation could not be the only reason for the malfunctions and that the installation of a longer hose would help reducing the bending load at the hose’s ends. In addition we found positions for the ends of the hose which lead to a significant load reduction.

 

Project Delphi: Wiring harness simulation in real time for length layout and validation of installation space considering the movement of the engine

In this video you can see the simulation of the branched wiring harness of a complete motor wiring. This simulation is very complex, for it contains very different wires with different rigidities and varying flexibility depending on the fastening. In the video you can see a user of the software manually move one single cable by moving a black clip. The resulting effects on neighboring and connected cables are visible, the particular load being displayed by color coding. Because of the real time simulation of IPS Cable Simulation, the software user can directly see the results of his own intervention.

 

Project Audi: Freely suspended and attached cables in the cockpit

In this video you can see a simulation of wiring harnesses with branching and wires which are either attached or freely suspended and carried along. Some of the cables are fastened by kinematical clips which are either body mounted or hanging freely. IPS Cable Simulation also offers an evaluation of the strains and the bending radii in real time.