Simulation
Identifying better Designs faster
We use various commercial software applications and inhouse solutions to provide our development departments and customers with reliable suggestions from the initial design phases. The advantage for LEONI and our customers: optimized development times with reduced need for physical tests.
Comprehensive possibilities & methods
LEONI’s interdisciplinary simulation includes the ability to simulate a wide range of materials and components. This includes electro-thermal effects, 3D cable routing, evaluation of dynamic loops and the effects of a variety of mechanical and vibration influences, to ensure optimal wire dimensioning and reliable and robust component design.
With digital functional simulation, LEONI is able to identify optimal future architectures of wiring systems and stable power nets. Supported by numerical methods, Simulation provides the technical health care of our development departments for optimized, reliable and robust cable harness and component design.
LEONI has a wide range of specific and validated dimensioning tools in order to identify optimal, application-specific cable cross-sections. This covers single- and multicore cables and wire bundles. Complete high voltage wiring systems, including connectors and terminals, are calculated by applying the thermal networks approach. As a Full Service (development) partner of the Mobility Industry, LEONI also covers the complete thermal simulation range of low voltage & high voltage power distribution, reaching from main fuse boxes, electromechanical power distribution, up to electronic switches and zonal controllers.
Mechanical simulation assists the development of a wide range of wiring harness components. This includes mounting forces of plastic clips, assembly forces of grommets , the evaluation of stress caused by mating processes as well as simulation driven sealing designs. Vibrational simulations are also a big part of the simulation support reaching from cable ducts up to complex high voltage power distribution boxes.
LEONI is able to predict the realistic routing behavior of cables including the influence of gravity, bending-, tension- and torsional stiffness. This applies for both static routing and dynamic loops, e.g. for wiring found in the axle, door or tailgates and for the wiring of HV motors. Here we also support the development departments and our customers with fatigue indication to determine reliable cable designs.
With Injection molding simulation we provide assistance from the design phase of the mold until the parameter setting for the first trials on the machine to ensure a high quality of LEONI’s plastic parts.
Voltage stability and failure tolerant power nets are the prerequisite for the use of safety-relevant driver assistance systems such as those already found in current and future wiring systems. Digital functional simulation supports the development of robust new architecture (concept) developments.
Development Digital twins of certain simulations provided by our experts in simulation enable our customers to evaluate the interaction of components at a system level and to optimize power management.
