Aircraft wire harness design: a digital model-based approach

The increasing electrical and electronic content of today’s aircraft is shifting the responsibility for critical functions to the aircraft wire harness and other electrical systems. This shift from mechanical to electronic enablement, coupled with more sophisticated electronic systems, has increased the risk for harness manufacturers.

To thrive in this challenging environment, aircraft wire harness manufacturers must modernize their methods.

A digital model-based flow unifies the previously fragmented domains of design and manufacturing and captures tribal knowledge held by experienced engineers through integrated design rules.

Download this white paper to learn how you can maintain profitability in aircraft wire harness manufacturing.

Aircraft EWIS

In the last five decades, power demands have increased more than tenfold. The aircraft electrical distribution system (Electrical Wiring Interconnect System or EWIS) has also become far more complex. As electrification continues, the role aircraft EWIS plays is much more important, making the growing EWIS complexity an even larger issue that needs resolving.

Today’s aircraft commonly contain electrical systems with more than 500 km of cables, over 100,000 wires and more than 40,000 connectors. All told, these added electrical components represent a significant portion of the total aircraft weight, which can add up to more than 7,000 kg of wire on larger aircraft. Growing EWIS complexity has substantially increased the risk aircraft programs face, especially as they transition to production.

Aircraft wire harness fabrication for the Digital Age

Aircraft wire harness fabrication is a critical aspect of overall program success. Growing EWIS complexity has substantially increased the risk aircraft programs face, especially as they transition to production. At the same time, platform OEM’s are required to implement more variants on the EWIS than ever before, and regulatory flight certification is more stringent than ever.

To gain competitive advantage, harness manufacturers have begun adopting a model-based approach with a digital solution that features a digital twin and digital thread at its center. With a solution like Capital™, harness manufacturers can manage complexity with a virtual model of the harness, while being able to communicate throughout the production lifecycle with the digital thread.

Download this white paper to learn how to bring your harness manufacturing into the digital age and thrive in the modern age.