Am 28 January 2025 we cordially invite you to our virtual event trend outlook The event offers exciting insights into current and future trends in the wiring harness industry as well as innovative technical approaches. The focus is on three presentations that will inform you about the latest developments and future-oriented solutions.

• From design to production: BordNetzSim3D as a digital bridge in on-board network development
  Presentation by Michael Koch, Technical Director & Research Coordinator, fleXstructures GmbH

  The on-board network forms the nervous system of modern vehicles and is facing major challenges due to new drive technologies, increasing networking and autonomous driving. The development of vehicle wiring harnesses is becoming increasingly complex as fragmented data landscapes and inhomogeneous structures complicate the processes.

  In the BordNetzSim3D research project, fleXstructures has developed a comprehensive digital solution together with partners such as Fraunhofer ITWM, Volkswagen and WeWire. This approach enables the physically secure design, precise validation and optimized production of cable harnesses. The developed toolbox, based on IPS Cable Simulation, sets new standards: It offers a physically correct representation of cable bundles in real time and covers the entire process from planning to assembly. The presentation shows how this simulation technology creates a seamless connection between virtual design and real production and increases efficiency and quality in on-board network development.

• Simulation of vibration loads on connector cable systems
  Lecture by Prof. Dr.-Ing. Jian Song, Ostwestfalen-Lippe University of Applied Sciences

  Mechanical stresses during operation have a significant impact on the reliability of electrical connectors and the connected cable systems. This presentation presents a simulation model that examines the relative movements of the contact partners under vibration. This is supplemented by laboratory tests in which the movements of a connector are analyzed using high-speed cameras and laser distance sensors.

  In addition, fretting wear and fretting corrosion tests shed light on the service life of electrical contacts. The results show that certain types of movement can lead to surface fatigue and delamination. The article underlines the importance of avoiding critical movement amplitudes to increase the service life and reliability of electrical connectors.

• Automotive Manufacturing 2035+: Future Outlook for the Wiring Harness

  Lecture by Prof. Dr.-Ing. Alexander Schönmann, Technical University of Ingolstadt

  The automotive production of the future is facing a profound change: New innovative production methods such as "Giga-Casting" and "Unboxed" mark a paradigm shift and set completely new standards in terms of efficiency, use of resources and sustainability. By radically simplifying and integrating production steps, such approaches could not only significantly reduce manufacturing costs and complexity from 2035+, but also make a significant contribution to reducing the ecological footprint of the automotive industry.

  However, these technological advances also bring with them a fundamental change in the business model: instead of the previous model change cycles, which are strongly focused on new car production and leaps in innovation, the future will be characterized by more flexible upgrade cycles. This new concept makes it possible to continuously improve existing vehicles through software and hardware upgrades throughout their entire life cycle. This saves resources, increases the longevity of the vehicles and meets customer needs more dynamically.

  The wiring harness plays a key role in this change. As a critical component of modern vehicles that enables electrification, networking and autonomous driving, it must meet the new requirements for modularity.

  This presentation provides a comprehensive insight into the technological developments and trends in automotive manufacturing with the corresponding implications for on-board networks. It highlights how these technological innovations not only contribute to increased efficiency and sustainability, but also to the strategic transformation of the entire automotive industry.

 
For those who were unable to attend live, documented recordings and presentations of the talks are available. The full agenda for January 28th and all documentation can be found further down this page.

The trend outlook on January 28, 2025 was a great success and met with a great response. The three presentations provided valuable insights into current and future developments in the wiring harness industry, including digital simulation methods, mechanical stress tests for connectors and the role of the wiring harness in future vehicle production.

For those who were unable to attend live, the presentations and recordings of the lectures are available. This means that the knowledge gained can still be used and discussed.

Special thanks go to the speakers for their exciting contributions and their willingness to share their knowledge with the community.

. documentation of the presented lectures:

• From design to production: BordNetzSim3D | Michael Koch, fleXstructures GmbH
• Simulation of vibration loads on connector cable systems | Prof. Dr.-Ing. Jian Song, TH OWL
• Automotive manufacturing 2035+: Future outlook for the wiring harness | Prof. Dr.-Ing. Alexander Schönmann, TH Ingolstadt

If you have any questions about the content or the speakers, we will be happy to put you in touch.