Wire harness designs: 5 revelations from mechanical engineers

Apr 16, 2024

Are you looking to enhance the efficiency and reliability of your Electrical Wire Harness (EWH) designs? Do you want to avoid the costly mistakes that often arise late in the production process? Mechanical engineers, tasked with the complex job of designing wire harnesses, are turning to automated validation tools to streamline their workflow and ensure compliance with industry standards. Here are five key insights from mechanical engineers on optimizing wire harness designs.

1. Early error detection saves time and money

A fundamental insight from experienced mechanical engineers is the significant cost benefit of detecting errors early in the design process. Automated software solutions that validate EWH designs for common errors can prevent the costly repercussions of late-stage detection, such as production delays and increased expenses. By identifying potential issues before they become entrenched in the production cycle, engineers can rectify problems without impacting the overall schedule or budget.

2. Standard compliance is critical

Wire harness designs must adhere to strict industry standards, whether it's AS50881 in aerospace, ISO 26262 in automotive, or IEEE 315-1975 in electrical applications. These standards ensure safety, reliability, and quality across all stages of production. Mechanical engineers emphasize the importance of software solutions that are up-to-date with these standards, ensuring that every design is compliant from the outset. The consistent application of industry standards not only minimizes the risk of post-production modifications but also streamlines the certification process.

3. Integration with CAD tools enhances efficiency

The integration of automated validation tools with Computer-Aided Design (CAD) software is a game-changer for mechanical engineers. This synergy allows for seamless design and analysis, enabling engineers to make informed decisions quickly. CAD-integrated software solutions help engineers visualize potential issues in real-time, facilitating a more intuitive design experience. This integration is particularly beneficial when dealing with complex wire harness layouts, where the spatial arrangement of components can significantly impact performance and manufacturability.

4. Collaboration between disciplines is key

Wire harness design is not an isolated task; it requires the collaboration of various engineering disciplines, including wire-harness engineers, system engineers, and manufacturing engineers. Mechanical engineers advocate for software solutions that promote interdisciplinary collaboration, allowing for a more holistic approach to design. Sharing insights and feedback across teams can lead to innovative solutions and a more robust final product. Effective collaboration tools within the software can help bridge the gap between different engineering perspectives.

5. Continuous learning and adaptation

The field of wire harness design is constantly evolving with new technologies and materials. Mechanical engineers stress the importance of continuous learning and adaptation to stay ahead of the curve. Software solutions that offer updates on the latest industry trends and materials can be invaluable. Engineers must be willing to adapt their designs to incorporate new advancements, ensuring that their wire harnesses are not only compliant but also at the forefront of innovation.

In a nutshell, mechanical engineers play a pivotal role in optimizing wire harness designs by leveraging automated software solutions for early error detection, adhering to industry standards, integrating with CAD tools, fostering interdisciplinary collaboration, and embracing continuous learning, they can significantly improve the design and manufacturing process. The insights provided by these professionals are instrumental in pushing the boundaries of what is possible in wire harness design, ultimately leading to safer, more reliable, and cost-effective products.