Property Predictor for the Simulation of Cable Bundles

该项目的目的是预测有效的弹性性能的电缆系统的装配模拟，考虑到非线性效应和载荷情况下弯曲和扭转之间的耦合。电缆系统一词在本项目中用作单根电缆、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、护套等）组成。这些电缆系统的组成取决于所需的功能和电缆特性。它对缆索系统的机械性能也有显著的影响，这在运动缆索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。车辆中通常安装总长度达2 km的电缆和电缆系统。根据车辆及其设备的类型，安装了多达900种具有不同功能和结构的电缆类型。由于汽车的数字化程度不断提高，这些数字也在不断增长。应用的多样性导致电缆系统中电缆类型的多种可能组合，因此系统的机械性能也会有所不同。测量每个电缆系统的机械性能在技术上是可行的，但成本高且耗时。此外，电缆系统的原型通常无法在早期开发阶段进行测量。确定索系统力学性能的一种更有效的方法是对索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 Cable Simulation，以模拟考虑扭转和弯曲变形耦合的索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的结果得到了增强，并进一步发展用于生产中电缆线束的模拟和布局优化。针对该项目的软件原型（以下称为ProP4CableSim）将包含混合属性模型（具有数据库组件的本构模型），该模型能够模拟具有耦合效应的大空间变形下缆索系统的非线性行为。这将扩展IPS电缆仿真的适用性到各种新的应用场景。

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.