Vibration analysis of Automotive cable routing: ensure durability and compliance in vehicle design.

Optimize cable routing for reliability under dynamic conditions

In modern automotive engineering, cable routing and harness wiring play a crucial role in ensuring the reliable operation of electrical systems in vehicles. These components are subjected to continuous vibrations, dynamic loads with mechanical stresses, which can lead to premature failures if the cable routings are not properly designed.

At Endego, we specialize in strength design and use advanced Computer-Aided Engineering (CAE) simulations to validate and optimize vehicle components. In a recent collaboration with a Client, Endego CAE virtual validation team conducted a vibration analysis and strength optimization of automotive cable routing, to ensure compliance with requirements of a leading car manufacturer.

Project challenge: meet vibration and strength requirements

The Client sought to verify the structural integrity and vibration resistance of cable routing in a passenger vehicle. The key objectives included:

• Assess stress levels in the harness wiring under operational vibrations.
• Ensure compliance with the OEM’s durability requirements.
• Optimize cable routing to enhance structural strength and minimize vibration-induced fatigue failure risk.

Given the complexity of modern automotive wiring systems, the challenge was to validate the fixation points, optimize routing paths, and enhance overall vibration resistance while maintaining ease of assembly.

Our approach: make advanced FE vibration simulations and consider values of sophisticated parameters

To meet the Client’s requirements, strength specialists at Endego, named also CAE virtual validation team, developed a high-precision Finite Element model of the cable routing system.

Key steps in the analysis:

1. Creation of a detailed FE model:
   • a computational model of the cable routing was developed in three dimensions; material properties, structural constraints, and fixation points were incorporated.
   • the attachment points were carefully modelled to capture real-world mounting conditions and cable movements.
2. Analiza wibracyjna z zastosowaniem obliczeń typu PSD:
   • power Spectral Density (PSD) vibration simulations were performed to assess how the cable routing behaves under realistic driving conditions.
   • the frequency response of the structure was analyzed to identify critical resonance zones where failure risk increases.
3. Calculation of RMS Stress Values:
   • the Root Mean Square (RMS) stress distribution was calculated across the required frequency range, identifying stress concentrations and potential fatigue failure points.
   • the results helped predict long-term durability and indicated areas for structural improvement.
4. Optimization of cable routing:
   • working closely with the Client’s engineering team, Endego specialists refined routing paths, fixation placements, and vibration-damping strategies to enhance durability.
   • the final design minimized excessive stress levels, reducing the risk of cable fatigue and failures over time.

Through simulation driven design improvements, the cable routing achieved optimal vibration resistance while meeting OEM’s specifications.

Project outcome: Reliable and Scalable Automotive Cable Routing

The optimized cable routing design, as validated by Endego CAE virtual validation engineers, ensure long-term durability and compliance with automotive industry standards.

The key benefits for the Client include:

• Reliable and vibration-resistant cable routing reduces the risk of electrical failures.
• Full compliance with the OEM’s strength and vibration requirements.
• Increased production of complex harness wiring support the growing demand in the automotive sector.
• Strengthened collaboration with a major car manufacturer, expanding business opportunities.

By leveraging FEM analysis and vibration optimization, Endego helped the Client to achieve robust and failure-free wiring system thus, enhancing vehicle reliability and safety.

At Endego, we offer structural analysis based on CAE simulations for automotive, rail and industrial applications. Endego expertise in advanced vibration analysis, fatigue strength assessment, and dynamic load simulations help manufacturers build more durable and efficient vehicle components.

If your company is looking for engineering support in harness wiring design, vibration validation, or dynamic stress analysis, contact us today! Our team is ready to help you optimize your automotive components for maximum reliability.

📩 Get in touch with us to discuss your project.