Motion Simulation and Test Comparison of Secondary Cable Flexible Wiring Harness Based on IPS
To address the frequent failure of the secondary cable harness in relay cabinets due to unreasonable de-sign arrangement and assembly,a new IPS-based method for motion simulation analysis and optimization design of flexible cable harnesses was proposed.This method focuses on multiple sets of secondary cable flexible wiring harnesses in a relay cabinet as the research object.Initially,by obtaining the material parameters and spatial struc-ture of the wiring harnesses,mechanical constraints and motion models of the relay cabinets and secondary cable harnesses are established using IPS software.Subsequently,dynamic simulation analysis is conducted for the flex-ible long wire harness,accurately locating faults in terms of geometric deformation,clearance,stress strain,bending,and distortion during movement.The optimal design based on IPS includes virtual assembly of wire har-nesses,dynamic analysis and risk evaluation,fatigue analysis of wire harnesses,and life prediction.Finally,simulation results are verified through physical field verification which demonstrates that the simulation effectively locates fault locations consistent with actual measurements while meeting standard requirements,thus effectively identifying hidden issues within wiring designs to improve reliability.
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