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The modular KSK design of Wiring Harness is to divide the wire harness assembly into different modules. Each module is regarded as a variable to realize the management of variables, and different wiring loom functions are realized through different arrangements and combinations of modules. The main feature of KSK design is to use enough redundant design to ensure that all known possibilities can be made. What is the modular KSK of Wire Harness, what are its advantages and disadvantages, and how to design it? This is the main answer of this paper. The following is the text.
The development and manufacture of modular wiring harness system, also known as KSK, is the abbreviation of German (KundenSpezifischerKabel), which means Customer-SpecifiedCa-ble. Literal meaning: customized according to customer requirements.
The modular design of wiring harness is to divide the wiring harness assembly into different modules. Each module is regarded as a variable to realize the management of variables, and different wiring harness functions are realized through different arrangements and combinations of modules.
KSK design is classified according to the degree of completion: complete KSK, partial KSK and pseudo KSK.
Complete KSK: customers can choose from all the physically realizable electrical functions of the whole vehicle and get the corresponding wiring harness (one-time development meets all requirements).
Part KSK: Customers can select the functions within a given range (one-time development to meet all the possibilities within a given range).
Pseudo-KSK: The appearance is the same as "complete KSK/ partial KSK" (after repeated development, only the configuration that the market has clearly needed is generally developed, but once the configuration and function change, it needs to be re-developed and verified)
The main feature of KSK design is to use enough redundant design to ensure that all known possibilities can be made.
KSK advantages:
(1) It can meet diversified needs;
Modular design is adopted, and the wiring harness on each car is tailor-made. And redundant wiring harness branches are not generated. Customers who purchase medium and standard cars do not have to pay extra fees for the extra 10 and 15 branch harnesses.
(2) High Design Integration and Complex Management;
With modular design, one drawing can be made into multiple wire harnesses of different models. And the traditional design method, every small change will have a new drawing. There may be hundreds or thousands of harness drawings derived from this. If the basic wiring harness of a certain model is changed, it will lead to the change of hundreds of drawings. The resulting amount of tasks is enormous. More seriously, it may become a barrier to limit designers' innovative thinking.
(3) Matching the mass use of standardized sub-parts to reduce the material cost;
(4) Platformization of matching vehicle types can reduce the cost and cycle of research and development;
Modular wiring harnesses are classified based on electrical function and layout. For designers like Kable-X, there is no need to find out whether similar models have been made before. He just needs to confirm whether there are new functional categories. If yes, the wiring harness design of the new function needs to be completed first. And then added to the function list. After the customer selects the vehicle configuration and the corresponding function list is generated, the wiring harness design can be completed by combining the wiring harnesses with different functions selected by the customer.
(5) Matching the standardization of functional modules to improve product quality. Generally, the adjustment of market demand can be met without engineering change.
After adopting the modular design, the original complex wiring harness design process becomes simple, standardized and systematic. It can effectively reduce and reduce the design and production risks of wire harness, thus improving product quality.
· KSK Disadvantages:
Initial design, high cost and long time-consuming verification;
The design environment requires high requirements (the overall development process of the company, the quality of employees, software and hardware, and the degree of standardization);
Late design changes are difficult;
The production process design is difficult;
Bicycle cost cannot be optimized.
Conditions for realizing modular design of wire harness
1) The main engine factory needs to establish the database needed for modular design. Such as connectors, terminals, wires, plastic parts and other information database.
2) Need a software that can realize data programming. Engineering software, such as CapitalHarnessSystem software, can be used to create wiring harness schematic diagram, 2D diagram, wiring list and so on.
3) It must be a harness supplier with modular design concept. Able to implement perfect ERP management, automatic operation equipment and well-trained engineering and technical personnel.
3.1 Division of Modules
The division of modules should be based on the experience of previous models, so as to facilitate the arrangement and combination of modules.
The principle of module splitting is: to ensure that the module covers all configurations of the vehicle, and the modules are clearly divided according to configuration or function, and loops or repeated loops cannot be omitted, and redundancy can be made when necessary to reduce the types of modules.
In the early stage of harness development, the modules must be clearly divided, and then each part is divided into different modules. At present, the electrical modules for the whole vehicle are divided into two types according to the functions of the parts: basic modules and functional modules.
The basic module, also known as the required module, is unique and has the highest priority. The parts in the basic module are mandatory configurations for all models, and these parts do not contain multiple configurations. At this time, the wiring harness drawing should have only one basic module, which is shared by all models.
The required module means that one of the sub-configurations in the required module must be selected regardless of the vehicle configuration; Optional modules indicate whether these modules need to be determined according to the customer's choice. If the customer chooses the configuration of optional modules, the sub-modules of functional modules need it, otherwise they don't.
Take the main harness assembly of a heavy truck as an example to explain.
Basic module, including lighting, wiper, doors and windows, door lock and other basic functions. No matter how customized the vehicle is, the function of this module is unchanged, so the unchanged part is classified as the basic module, and this module is also the most universal.
Engine function module, including circuits related to engine control. Such as accelerator pedal, brake switch and exhaust auxiliary brake. Because commercial vehicles will choose different engines according to customer customization, this part of the function is classified into a module to realize variable management.
ABS function module, including ABS-related functions, such as wheel speed signal, solenoid valve control signal, etc. Because commercial vehicles will choose different ABS systems according to customer customization, it is regarded as a separate module to realize variable management.
Comfort module, including car refrigerator, skylight, MP5 and other comfort functions. According to different customers' choices, this module is regarded as a separate module.
After the module division is completed, the basic module, required functional module and optional functional module are set and installed in advance in the system. If the selected module is repeated or omitted, the system will report an error, which is beneficial to the reverse investigation of the wiring harness with multiple modules and reduces the probability of module errors.
3.2 Component Module Attribute Division
After the module is determined, the sub-parts such as connectors, terminals and plastic parts on the wire harness are divided, and each sub-part should have a module attribute.
For connectors shared by different modules, connectors are generally classified according to the number of holes, and the connectors are classified as modules with more holes.
3.3 Harness Diagram Generation
Using the modular design method, different wire harness assemblies can be drawn together, reducing the number of drawings, which is convenient for technical management.
3.4 Development Verification
The module accuracy after wiring harness collocation is too large to be fully verified in kind, so the following strategies are generally adopted in each verification link.
1) Virtual verification: With the help of special design software, the feasibility of matching each module is simulated and analyzed.
Its advantages are short time and low cost. The disadvantage is that it is impossible to predict the unexpected situation in the actual production process of wire harness.
2) System verification: Select several wire harness assemblies with high, medium and low configurations to confirm the feasibility of the wire harness module. The advantage is that it can simulate the verification of real vehicles, but the disadvantage is that only some vehicles can be verified, and it is impossible to ensure that all configured vehicles are verified. Considering the cost, cycle and other aspects, most modular wire harnesses are verified by this method.
3) Real vehicle verification: verify the option strategy with the same system to ensure that all modules are covered by the harness assemblies carried by all test vehicles. The advantage is that it can ensure that vehicles with various configurations are verified and fully verified. Disadvantages are the demand for more vehicles, long verification period and high cost.
4 KSK Outlook
The system development of KSK mode of wire harness requires the OEM and suppliers to establish a complex information interaction system, and at the same time, it requires high personnel in design, production, logistics and other aspects. However, the modular production of wire harness KSK can greatly shorten the development cycle and save costs.
With the increasing demand of consumers for vehicle configuration and personalization, KSK harness design is the initial embodiment of customer customization. Domestic self-owned brand cars are booming, and the wiring harness has great potential in the direction of modular design. In the end, KSK's wiring harness production mode will become the mainstream, and it will not be limited to the automobile field, but will continue to expand into different fields to achieve high-complexity production in mass production, so that everyone can experience customized products that fully meet their own needs.
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