Inverse Stiffness Characterization of Electrical Cable and its Importance in Structural Validation

Abstract

<div class="section abstract"><div class="htmlview paragraph">An automotive wiring harness is the backbone of the electrical architecture, and it runs throughout the vehicle to transmit electric power. In a virtual simulation, the mechanical properties of individual strands cannot be considered for the harness bundle (or) cable. Predicting the mechanical properties of electrical cables is a challenging task, and it has major setbacks in virtual simulation. This paper proposes an approach to find out the mechanical properties of an electrical cable and explains how the values are used in virtual simulation.</div><div class="htmlview paragraph">Cable modelling is represented as a lumped mass (or) modelled with a 1D element in the conventional FE modelling approach. In the first part of the study, finite element modelling and material modelling procedures of high and low-voltage electrical cables routed through brackets and troughs are discussed. Mechanical properties are developed using an inverse stiffness characterization method from bench level physical testing in static and dynamic conditions. The physical setup is replicated in a virtual simulation. The material properties used in simulation are iterated until the results match the physical testing results.</div><div class="htmlview paragraph">Material properties derived from the inverse stiffness approach are tested with various applications, and it gives promising agreement in correlation and prediction with physical test results. A Test Vs CAE correlation exercise has been performed for various problems like random vibration analysis, mechanical shock test, and engine roll simulation. The main objective of the paper is to present a suitable material calculation method for electric cables that encounter structural problems in static and dynamic conditions. The test-based inverse stiffness characterization method is observed as an efficient method for the finite element material modelling of cables. Adopting the proposed method, high manual effort and computation time involved in micro-level modelling of cables can be avoided.</div></div>