Challenges in DRC implementation for complex wire harness systems

The complexity of wire harness systems has escalated with the increasing incorporation of sensors, power, and computing capabilities into modern technology.

Design Rule Checks (DRCs) play a pivotal role in refining the design process of such wire harness configurations. They aid designers in reducing waste, minimizing costs, optimizing assembly processes, and ensuring the manufacturability of products.

However, the implementation of DRCs is fraught with challenges, particularly as the complexity of connection systems surges. In the below we highlight the requirements of DRC implementation, focusing on the difficulties faced when dealing with connection systems comprising hundreds of wires and numerous connectors.

We were dealing with connection systems that had hundreds of wires with 30, 40, 50 different connectors

Complexity of modern wire harnesses

Connection systems with a high number of wires and connectors present a significant challenge in terms of design and validation. The intricacy of such systems demands sophisticated software and a high level of engineering expertise. As the number of components within a wire harness increases, so too does the difficulty of ensuring that all parts work together seamlessly. This complexity can lead to a greater potential for design errors, which DRCs are intended to detect and prevent.

Integration issues between CAD tools

A key issue in the implementation of DRCs is the integration of mechanical and electrical Computer-Aided Design (CAD) tools. Not all systems offer seamless integration, resulting in a disjointed design process that can necessitate manual checks. This disconnection between schematic capture and mechanical design can lead to inefficiencies and errors that are not easily detected by validation tools. The lack of comprehensive data capabilities for design validation exacerbates this problem, as does the incomplete information within libraries.

Scaling challenges

The need to scale DRCs to accommodate the varying complexities of wire harnesses is another significant challenge. Wire harnesses can vary in bundle diameters, protective coverings, and layers, adding to the complexity of the validation process. The tools used must be capable of handling these variations to ensure accurate design checks.

Industry Evolution and Regulatory Changes

The dynamic nature of the industry requires constant updates to DRCs and libraries to reflect changes in parts, specifications, and regulatory requirements. Environmental standards, in particular, are subject to change, and designs must be adaptable to meet these evolving demands. This necessitates a proactive approach to design and validation to stay ahead of industry trends and regulations.

Training and Expertise

The sophistication of modern wire harness systems requires a high level of expertise. Engineers must be deeply experienced to navigate the complexities of design and validation. Training is essential to equip design teams with the skills necessary to implement DRCs effectively. However, acquiring and maintaining this level of expertise is a challenge in itself, particularly in a rapidly evolving industry.

Considering the detailed challenges outlined above, it is our opinion that while DRCs are a critical component in the design of wire harnesses, their effectiveness is contingent upon addressing the integration, scaling, and data handling issues that currently plague the process. The industry must invest in leveraging more sophisticated software tools that can handle the complexity of modern wire harnesses and improve the integration between mechanical and electrical CAD systems.

Furthermore, the dynamic nature of industry standards and environmental regulations requires a proactive approach to updating DRC protocols and libraries. This necessitates a continuous investment in research and development to keep pace with technological advancements and regulatory changes.

The scaling problem is particularly pressing. As designs become more intricate, DRCs must evolve to accommodate the increased complexity without compromising on efficiency or accuracy. This will likely involve the development of more advanced algorithms and the adoption of machine learning techniques to enhance predictive capabilities.

Lastly, the human element cannot be overlooked. The demand for experienced engineers with deep expertise in wire harness design is higher than ever. The industry must prioritize the training and development of its workforce to ensure that the necessary skills are not only available but also continuously updated in line with evolving technologies and standards.

About Mr Arik Vrobel

For over 30 transformative years, Arik led the evolution of El-Com Systems into a pinnacle of excellence in Electric Wire Harnesses (EWH) for global enterprises. In his final 5 years, he steered El-Com to become the foremost provider of engineered harnesses for the commercial-space sector, supporting groundbreaking projects on space platforms.

Since its acquisition by Winchester Interconnect, driven by his entrepreneurial spirit, Arik founded Cableteque, a beacon of innovation offering AI-based CAD tools to enhance and validate engineering designs of EWH, inspiring the industry with his vision for impactful technological advancement.