Endego’s comprehensive support for electric 3-wheel vehicle development.

Challenge: navigating complex design constraints

The US start-up developing its electric 3-wheel vehicle needed to establish a new harness development process that integrated seamlessly with other development areas. The harnesses required to cover both high-voltage (HV) and low-voltage (LV) areas ((incl. CAN/LIN data transmission), emphasising using available components in the US market and designing new elements to optimise future production costs.

Solution: Endego’s integrated approach

Endego deployed an entire harness development team, sending a resident engineer to the USA to streamline communication and real-time problem-solving. Our team leveraged years of experience to integrate the necessary design tools and develop additional components. In collaboration with our CAE department, we conducted dynamic and thermal simulations of the harnesses, adhering to US market design standards. We also adapted European component databases to meet US requirements, ensuring seamless integration and cost efficiency.

Key elements of our solution included:

• Full Wire Harness Development Team: Endego provided a dedicated team with extensive experience working with European OEMs, systems, processes, and standards.
• Resident Engineer in the US: A resident engineer was sent to the United States to facilitate close collaboration with the client, ensuring smooth communication and real-time issue resolution.
• Tools Integration for Harness Development: Endego integrates specialised tools for designing and developing wire harnesses.
• Design of HV and LV Harnesses: The team developed complete High-Voltage (HV) and Low-Voltage (LV) harnesses, including data transmission via CAN/LIN protocols.
• Dynamic and Thermal Simulations: Endego conducted dynamic and thermal simulations that complied with US market standards.
• Component Database Adaptation: The European component databases were adjusted to meet the requirements of the US market.
• Compliance with Functional Safety Standards: The team ensured compliance with ISO 26262 Functional Safety standards and adapted them to the US-specific conditions and components.
• Project Timeliness: The client was able to complete the project within the expected deadlines thanks to the efficiency and collaboration provided by the Endego team.

Technologies: Advanced tools and expertise

Our solution utilised a range of advanced technologies and methodologies:

• Functional Safety (FUSA): Incorporating functional safety principles to meet rigorous safety standards.
• High Voltage (HV) and Low Voltage (LV): Expertise in designing both HV and LV harnesses.
• VeSys and NX Routing Electrical: Leveraging these tools for precise and efficient electrical system design.
• LDorado: Employing LDorado for advanced development of production drawings.
• Communication protocols: Integrating CAN and LIN protocols for reliable communication within the vehicle.

Expectations and standards for complete car development:

• Tool integration: Increasing reliance on integrating multiple design tools for streamlined workflows.
• On-site engineering support: Growing need for on-site engineering support to facilitate real-time problem-solving and adaptation.
• Functional safety: Emphasis on incorporating functional safety principles to meet stringent safety standards.
• Component cost efficiency: Focus on using existing market parts to reduce costs and streamline production.
• Comprehensive simulation: Utilization of dynamic and thermal simulations to validate designs and ensure compliance with standards.

Endego’s competences

Endego’s harness design and development competences are extensive, covering every aspect from initial electrical diagrams to final production. Our capabilities include:

• Process expertise: Assisting clients in implementing specific development processes to streamline project execution.
• Production implementation: Implementing products into production efficiently to ensure seamless integration and high quality.
• Electrical diagrams: Creating electrical diagrams that serve as the blueprint for harness designs.
• Packaging.
• 3D models and 2D drawings: Developing 3D models and 2D manufacturing drawings.
• Component design: Designing and optimising individual components.
• Simulations.
• FuSa.

For more detailed insights into our competencies, visit our Wiring Harness page.

Endego’s recent project with a US startup highlights our ability to overcome complex design challenges and deliver expert harness development solutions. By leveraging cutting-edge technologies and our extensive expertise, we successfully helped our client bring their electric 3-wheel vehicle to market on time.

For inquiries or more information about our services, feel free to contact us.