Zonal architectures
Leoni is redeveloping the wiring system
Lower overall costs, a smaller carbon footprint and potential for new supply chains and production processes are Leoni's goals when it comes to wiring systems. The key to this is the zonal architecture, which allows a higher degree of automation in wire harness production.
Today, an on-board network usually consists of more than 100 control units and 1000 individual cables, and the trend is rising. »This is slowly pushing the limits of what can be reasonably handled in production and final assembly. Especially in view of the trend towards autonomous driving and networking, which will lead to even more electronics and cables in the wiring system,« says Ingo Spenger, Leoni COO and board member. His conclusion: »We have to rethink the wiring system!«
Intelligently partitioned partial cable harnesses
The solution is: zonal architecture. Researchers, engineers and manufacturing experts at Leoni divide the previous large, heavy and complex harness into several intelligently partitioned sub-harnesses. Each sub-cordset is connected to a zone controller that performs certain sub-tasks independently.
»At Leoni, we think product and production holistically from the very first sketch, for maximum efficiency in development and implementation,« explains Walter Glück, CTO of Leoni's wiring systems division WSD.
Lower transport costs, more stable supply chains
The advantages for carmakers are manifold. Wire harnesses for individual zones are more manageable and thus easier to automate in production and to an increasing degree. The growing degree of automation relativises the importance of labour costs, allowing production sites to move closer to customers' plants again.
This reduces transport costs and the carbon footprint. At the same time, the resilience of supply chains to external disruptions increases. Furthermore, automation leads to better manufacturing quality and traceability of all production processes.
Last but not least, intelligently tailored sub-harnesses - for example for bumpers - are very similar across different vehicle models, which is why they can be produced on one line. This reduces fluctuating capacity utilisation due to volatile customer call-offs. In addition, they simplify and make more flexible the final assembly of the wiring system in the customer's plant, which enables the OEM to reduce the total cost of ownership.
More functions with less space and weight
The demands on the wiring system are increasing. More and more functions and data have to be mastered - in less and less space with less and less weight. »With the zonal approach, we enable car manufacturers to design completely new wiring system architectures. Compared to today's customised wiring systems, they are, according to our initial calculations, ten to prospectively 30 percent lighter and, at the same time, more favourable in the overall cost calculation for the OEM,« says Glück.
The wiring system congress of Elektronik automotive
On 21 September 2023, Elektronik automotive will hold the Wiring Systems Congress at Landhut University of Applied Sciences. Zonal architectures and supply chain resilience will also be a topic there.
The programme for the Bordnetz Kongress is already online, and registration is currently open at the early bird rate.
