Case Study 2

Electrical Harness Design

The client is a leading manufacturer of small business aircrafts.

Business Challenge

The requirement was to design and develop electrical harnesses for aircraft systems based on sketches and routing considerations.

This job was accomplished using software tools (UG NX5) and geometric models of the aircraft. This task was carried out by engineers having field experience in electrical harness routings and associated components. 3D models were developed to assist in routing of harnesses and 2D models were developed to create drawings for manufacturing. Special attention was paid to EMI/EMC and grounding requirements. Component selection (cables, connectors, clamps, splices, terminal blocks), electro-magnetic shielding, number labeling were included as part of harness development. The team was well versed in the standards applicable to aircraft harness development.

Benefits Accrued:

The productivity improved significantly with the use of software tools and digital mock up of the aircraft. It was possible to develop optimum harness routing using the digital mock up. No physical prototype of the aircraft was required thereby reducing cost and development time.

Performance delivered

Our performance improved the delivery schedule of the products with schedule and effort variation less than 5%. The error injection varies from 20- 5 % during our internal delivery. However, functional error in testing is 0% to the customer with non-technical error having maximum to 5%. The correction cycle for any defect is not more than 2 per delivery.