IPS Cable Simulation

3D mechanical design, optimization, virtual assembly and digital mock-up of wires, wiring harnesses and hoses

Validate your flexibles in real-time

By using IPS Cable Simulation, validated results regarding flexibles and related parts are achieved early in the product process. This leads to great savings in terms of time and money due to less prototyping and iterations.

Join the way from an iterative hardware based process to a simulation oriented approach.

Quality improvement and quality assurance

Applying the software in design, virtual assembly, DMU processes and for troubleshooting results in higher product quality and improved durability of flexible parts.

Interdisciplinary cooperation

IPS Cable Simulation serves as a common fast decision platform bringing together different divisions of a company in all phases of the product process. This helps detecting flaws and assures product quality

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Benefits for design engineers, managers and processes

First time right quality for concept of virtual cables, tubing and design of flexible components
Virtual approval allows reduction of hardware cost for validation
Interactive user-friendly interface due to real-time calculation
Starting a comprehensive digital way of working with your flexibles
Now available digitally, validated cable concept 3 years before SOP

Automatic routing

In design processes, engineers find optimum routings, lengths and shapes for flexible components interactively by applying IPS Cable Simulation. It is either possible to route a cable or a hose from scratch or to make your CAD geometry flexible.

Key features:

Design of flexible parts with or without predeformation, interactive optimization of routings and lengths
Customized clips, kinematical clips, clip database

Measurement and visualization of contacts, collisions, stresses and strains

By the interactive work with IPS Cable Simulation it is possible to view, analyze and optimize flexible componentes in real-time.

Key features:

Detection of collisions
Optimization of motions
Calculation of large deformations between moving parts
Bending radii, stresses …

Automatic optimization

There is a complete new way to optimize length and attachments of the cable with respect to any cable value measure or distance measure to surrounding geometries. This means another saving by 80 – 90 % of time by checking multiple criterias at once.

Design space optimization through motion envelopes or tolerances

For design engineers the required space for cables and hoses is a crucial challenge. In order to do a motion analysis of flexible components a real-time solution is needed. In addition IPS Cable Simulation provides capabilties such as:

Envelopes of needed installation space for variations of length and fastening
Tolerance analysis
Swept volumes for flexibles and rigid bodies
Comparison of the designed space (envelopes)

Analyze and validation

By applying IPS Cable Simulation, risk factors such as tensions, small bending radius and points of collision can be identified. Additionally, various parameters such as material properties and cable lengths can be optimized interactively in real time. Several analysis features regarding bending radius, torsion, forces, tension and distances ensures a validated result.

IPS Cable Simulation does not use time-consuming finite element methods. Instead, a physically correct beam model is used. As a consequence, the computing time is considerably reduced while the maximum accuracy is achieved.

“IPS cable simulation provides high precision predictions and quality evaluation of flexible hoses and cables with motion. This frees design engineer from path prediction, and has great effect for design quality.”

Tomohisa Kaneko, Development Control Sect., Engineering Control Dept. Engineering Div., SUMITOMO CONSTRUCTION MACHINERY CO.,LTD.

“IPS simulation software realistically reflects the situation in the assembly space three-dimensionally in the form of animations, making it possible to calculate points of contact, collision and high stress with great precision.”

Matthias Mehnert, Leiter Service-Center Großmehring / Fellbach, WEWIRE Coroplast Group, April 2020