E/E architectures in the software-defined vehicle

The wiring harness as a nervous system

In the context of the Software-Defined Vehicle (SDV), the wiring harness evolves from passive cabling into a complex E/E system. High-voltage integration, data rates for ADAS, and high-performance computing make the layout the critical path of the system architecture. Those who rely on conventional, isolated workflows instead of integrated co-simulation and cross-system engineering risk serious errors during vehicle integration.

Precision under high pressure

Automated 3D packaging-space checks to prevent installation conflicts and impermissible bend radii in highly compact wiring systems.

E-mobility intensifies the fight for every millimetre of packaging space. Battery packs and power electronics take up valuable packaging space and displace traditional cable routes.

The result: the physical routing of wiring harnesses is often finalised only at a stage when changes are extremely costly. Without early, automated 3D packaging-space checks, the risk of impermissible bend radii and packaging conflicts increases dramatically. The challenge for engineers is to digitally validate technical feasibility before the first physical prototype is built, so as not to jeopardise time-to-market.

Seamless design-to-factory

Synchronisation of engineering centre and plant through automated bills of materials and drawing derivation for complex customer-specific wiring harness (KSK) electrical systems

At the same time, customisation is driving process complexity to unprecedented levels. The trend towards customer-specific wiring harnesses (KSK) results in billions of theoretical configurations.

Managing these volumes of data manually is hardly feasible in terms of auditability. In a globally networked production environment, design changes must flow flawlessly from the engineering centre to the plant within hours. Manual media discontinuities—such as retyping bills of materials or manually scaling drawings—are the primary cause of costly scrap in this high-speed environment.

Single Source of Truth
with smartCable

The bridge between engineering and production

Forward-looking OEMs and suppliers address these risks with a consistent Single Source of Truth (SSoT). The goal is a seamless digital twin that maps the entire lifecycle: from the initial logical sketch through virtual engineering to the final NC interface in production.

Only a deeply integrated toolchain that "understands" the physical properties of wiring harnesses enables automated validation routines and error-free scalability. Our specialised software suite delivers exactly this end-to-end workflow—precise in design, efficient in production.

Digital engineering with V5HAutomated production with MS Cable

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