We aspire to develop complex wire harness systems.
A wire harness connects all electrical and electronic components in a vehicle. It supplies power and transmits signals. And, as the megatrends of e-mobility, car IT and autonomous driving continue to grow, such systems are becoming increasingly complex. From examining individual components to developing finished wiring harnesses, we are specialists in the entire development process. As a result, we offer an extensive service portfolio, from designing the wire harness architecture and defining the overall concept to electrological aspects and producing the circuit diagram, through to cable routing and developing individual components. At the end of the formation process, we also construct prototype and template wire harnesses and conduct testing on them. What’s more, we have set ourselves the task of making the development of wire harnesses more efficient and automating this process using proprietary software. This allows us to develop wire harnesses for the next generation of vehicles.
Our wire harness development services
We develop complex module variants to control customer-specific wiring harnesses. As part of this, we work on system circuit diagrams and wiring diagrams in common tools such as EB Cable, E3D Zuken and Mentor Capital – from the initial concept to series maturity. Our service spectrum is completed by documentation, which we tailor to your individual requirements. Due to rising data rates, growing demands are also being placed on physical transmission infrastructure. As a result, we are already testing the functionality of new bus systems, such as CAN FD, and offer suitable simulation environments for this purpose.
Whether we’re faced with tight installation spaces, radiation limits, EMC requirements or complex production processes, we take care of cable routing and geometric integration in CAD throughout the defined architecture of the wire harness. We apply our expertise in development processes to the entire vehicle and work in close coordination with other specialist areas, such as interior and exterior designers and body in white specialists. To identify all critical paths in functions, components and under different environmental conditions at an early stage of development, we analyse the system in advance through modelling and simulation. As a result, you benefit from our interdisciplinary collaboration and our use of IPS Cable Simulation. We simulate the components, the environment and the interactions between components and also take care of all necessary variant analyses.
From fixing elements and wiring ducts to cable runs, sleeves and housings for control units complete with mountings, as well as routing cables in 3D, we develop all accompanying components for wire harnesses. Finally, we test these components to make sure they function properly. We test almost all load and testing scenarios on proprietary test benches, in climatic chambers, on shakers, in corrosion chambers, in real test runs and also in virtual environments.
Project and zonal management completes our service portfolio for the development process. Our specialists act as interdisciplinary interfaces between you and specialist departments. By working in close coordination with the relevant specialist areas, we guide the entire manufacturing and development process for wire harnesses, including diagnosing issues, troubleshooting and giving approval. Serving as an interface and cross-functional actor, we supervise concept and series development, guide change management and supervise series production. We keep an eye on quality, cost and time considerations at all times.
In the automotive industry, the pressure to innovate is intense. New vehicle generations are expected to be lighter, consume less energy and, at the same time, offer the driver and passengers more functions. For wire harnesses, this means new materials, processes and technologies. We have identified this trend as a challenge and thus moved to pool our competencies in a central area for wire harnesses, concentrating in particular on trend scouting as well as technological and tool development.
From the electrical system architecture to the wire harness for the cockpit, chassis and stand-alone systems, we provided advice and support through the development of CitE, a fully electric truck for urban deliveries, manufactured by MAN. This project was set up in just 18 months – an achievement made possible in part thanks to our experienced team and the interdisciplinary and cross-location collaboration at ASAP. Integrated networking is also the basis of our distribution concept, the different voltage levels (24V, 48V and HV) and the resulting specific requirements regarding insulation (safety with high voltages), EMC and impermeability.
Communication is everything.
In light of the megatrend of autonomous driving, it is conceivable that system complexity will continue to rise. In autonomous vehicles, for example, all safety-related functions require redundant protection. By developing ASAP Wire Architect (AWA), we have created a software solution that automates large parts of wire harness development. AWA facilitates the transfer of data and communication between separate development tools, such as EB Cable, LDorado, Catia, E3D Zuken and Siemens NX. The software significantly reduces the error rate from human data transmission: AWA automates the import and export of data as well as the reconciliation of design drawings and initiates corresponding changes in the programs. This means we can generate datasets for wire harnesses faster and more efficiently and validate them more effectively.
Robert Zeller – Projekt manager, Wire Harness Development.
“As one of the first employees on the Wire Harness Development team, I saw our initial work at first hand. I was able to dip into lots of different topics, get actively involved and establish a good network. Today, it’s great to see what we’ve achieved together in recent years – from three employees in late 2011, we now have 100 employees involved in wire harness development across Germany. That really makes me proud!” Robert Zeller, employee, Wire Harness Development