Property Predictor for the Simulation of Cable Bundles

本项目的目的是预测电缆系统的有效弹性特性，用于装配仿真，考虑非线性效应和载荷箱弯曲和扭转之间的耦合。术语电缆系统在本项目中作为单个电缆、电缆束和电缆线束段的统称。在这种情况下，单根电缆和电缆束代表了电缆线束段的不同层次以及独立的电缆系统，因为单根电缆已经由许多不同的组件（电线、屏蔽层、护套等）组成。这些电缆系统的组成是由所需的功能和电缆特性决定的。它对电缆系统的力学性能也有重要的影响，在运动电缆系统的几何设计中具有不可忽视的重要性，并决定性地决定了应用中的使用寿命。电缆和电缆系统的总长度可达2公里，通常安装在车辆中。根据车辆和设备的类型，安装了多达900种不同功能和结构的电缆。由于汽车的数字化程度越来越高，这些数字还在不断增长。各种各样的应用导致电缆系统中多种可能的电缆类型组合，因此系统的机械性能也各不相同。测量每个电缆系统的机械性能在技术上是可行的，但成本高昂且耗时。此外，在早期开发阶段，电缆系统的原型通常无法用于测量。一种更有效的确定电缆系统力学性能的方法是对电缆的力学性能进行实验测量和基于数据的系统性能预测。该项目的目的是扩展IPS电缆模拟，以模拟考虑扭转和弯曲变形耦合的电缆系统的非线性弹性空间变形行为。为此，在DFG前身项目中获得的知识通过Fraunhofer MAVO UrWerk的结果得到增强，并进一步开发用于生产中电缆线束的模拟和布局优化。本项目的软件原型（以下将称为ProP4CableSim）将包含一个混合属性模型（具有数据库组件的本构模型），该模型可以模拟具有耦合效应的大空间变形下电缆系统的非线性行为。这将扩大IPS电缆仿真的适用性，以适应各种新的应用场景。

The aim of this project is to predict the effective elastic properties of cable systems for assembly simulation, taking into account non-linear effects and the coupling between the load cases bending and torsion. The term cable system is used in this project as a collective term for single cables, cable bundles and cable harness segments. In this context, single cables and cable bundles represent different hierarchical levels of a cable harness segment as well as independent cable systems, since single cables are already composed of a multitude of different components (wires, shielding, sheathing, etc.). The composition of these cable systems is determined by the required functions and cable properties. It also has a significant influence on the mechanical properties of the cable system, which are of non-negligible importance in the geometric design of moving cable systems and decisively determine the service life in the application. Cables and cable systems with a total length of up to 2 km are typically installed in a vehicle. Depending on the type of vehicle and its equipment, up to 900 cable types with different functions and structures are installed. Due to the increasing digitalisation in cars, these numbers are constantly growing.The variety of applications results in a multitude of possible combinations of cable types in a cable system and thus the mechanical properties of the system vary. Measuring the mechanical properties of each cable system is technically possible, but costly and time-consuming. In addition, prototypes of the cable systems are usually not available for measurement in early development phases. A more efficient method to determine the mechanical properties of a cable system is the experimental measurement of the mechanical properties of the cables and the data-based prediction of the system properties.The aim of the project is to extend IPS Cable Simulation for the simulation of nonlinear elastic spatial deformation behaviour of cable systems considering the coupling of torsional and bending deformations. For this purpose, the knowledge acquired in the DFG predecessor project is enhanced by the results of Fraunhofer MAVO UrWerk and further developed for use in the simulation and layout optimisation of cable harnesses in production. The software prototype aimed at in this project, which will be called ProP4CableSim in the following, will contain a hybrid property model (constitutive model with databased components), which enables the simulation of non-linear behaviour of cable systems under large spatial deformations with coupling effects. This will expand the applicability of IPS Cable Simulation to a variety of new application scenarios.