Advances in Wire Harness Design for Autonomous Vehicles

The rise of autonomous vehicles (AVs) has launched a transformative period within the automotive industry. As these vehicles evolve in sophistication, the intricacies of wire harnesses, which underlie them, grow exponentially. In this blog, we’ll explore the latest advances in wire harness design for autonomous vehicles and highlight the pivotal role of Zuken’s E3.series in this journey.

The Evolving Role of Wire Harness in Autonomous Vehicles

In traditional vehicles, the wire harness is a component that manages basic functions such as lighting, audio, and air conditioning. While the wire harness design is vital to these functions, it is not considered the most significant design within the vehicle.

In modern vehicles, however, the significance of wire harnesses has been completely transformed given the advent of autonomous vehicles and their associated technology. Wire harness design complexity continues to increase as vehicles expand in functionality. Advanced functions encompass sensor data transmission, real-time decision-making, and vehicle-to-vehicle communication.

To support these functions, manufacturers integrate more sensors and electronic components into today’s vehicles, many of which require significant bandwidth. More digitized data and complex vehicle subsystems necessitate a design that can transport increased amounts of data and power throughout the vehicle. Hence, the wire harness has become substantially larger, heavier, and more relevant to design than ever before.

A New Age of Wire Harness Design

The industry has witnessed several innovations in response to these challenges, including:

• Modular Designs: Allows for easy replacement or upgrading of specific sections without the need to overhaul the entire system.
• Smart Materials: Introduced to reduce wire harness weight while ensuring its efficiency and durability.
• Integrated Software Solutions: Empower engineers to simulate and test wire harness design in virtual environments, ensuring optimal real-world performance.

Zuken’s E3.series: A Paradigm Shift in Wire Harness Design

Zuken’s E3.series software supports this rapid innovation and transformation happening in the field of vehicle wire harness design. Specifically, E3.series provides two robust tools — E3.formboard and Harness Builder — which make E3.series ideal for addressing specific design challenges.

E3.formboard is a specialized module within the E3.series that focuses on the creation of nail board or pegboard documentation for wire harness manufacturing. The module simplifies the creation of nail boards by enabling designers to generate detailed 1:1 scale drawings directly from their electrical design data. This ensures that the nail board accurately reflects the intended design, reducing the chance of error during the assembly process.

Moreover, E3.formboard provides a range of tools that allow for easy modification and customization of the nail board design. Whether it’s adjusting the placement of components, adding annotations, or modifying wire routes, E3.formboard ensures that designers have complete control over the final output.

Additionally, the E3.series offers an integrated module, Harness Builder for E3.series, specifically designed for harness manufacturers. It offers a comprehensive suite of tools to support the entire harness manufacturing process, from initial quotation and estimation to final assembly and testing. A standout feature is its ability to quickly document a complete harness, whether based on a detailed drawing or wire list. This ensures that manufacturers have all necessary information readily available, reducing the chances of oversights or errors.

Furthermore, Harness Builder provides automation capabilities to streamline critical aspects of the production process. It can automatically generate pricing information, lead times, and assembly time calculations based on design elements. This reduces manual intervention while ensuring that derived data is consistent and accurate.

The comprehensive toolset and extensive capabilities of Zuken’s E3.series provides an effective solution for wire harness design, empowering engineers to steer the future autonomous vehicle transportation.