Missing or unreliable cable models make precise simulations difficult and can lead to safety-related aspects being only partially taken into account. In order to obtain reliable data for simulation-based development, Kube GmbH Ingenieurbüro has been working closely with the Fraunhofer Institute for Casting, Composite and Processing Technology (IGCV) for several months. The aim of the cooperation is the comprehensive testing and validation of high-voltage cables for automotive applications.
Coordinated by project manager Christina Aust, the cables are systematically tested in the test laboratory using standardized procedures. Various test setups enable the reconstruction of mechanical loads under controlled conditions in order to specifically test where protective measures are necessary. Within the test setups, the cables are subjected to different forces in order to simulate realistic automotive scenarios – including crash simulations – and to determine the load and failure limits of the cables.
The test results determined by Fraunhofer IGCV are analyzed in close consultation with Vitali Gerbershagen, Product Owner KAB3L® at Kube GmbH. They form the basis for further modeling and simulation of the high-voltage cables in the FEM (Finite Element Method). Kube GmbH evaluates the data in detail, checks the quality of the results and then integrates them into the Kube KAB3L® Database. On this basis, loads can be simulated precisely and reliable recommendations for safe and customized installation can be derived.
Kube GmbH would like to express its gratitude for the successful collaboration with Fraunhofer IGCV and looks forward with confidence to the upcoming series of tests. At the same time, we would like to thank Fraunhofer IGCV for mentioning us in its latest press release: E-Autos sicherer machen – Fraunhofer IGCV
Project Insights
“The main challenge was to accurately simulate realistic stress scenarios for the high-voltage cables. Every mechanical stress had to be precisely controlled in order to obtain reliable data for simulation-based development. Using standardized test setups, we were able to identify the critical stress points and specifically test where concrete protective measures were required.”
Christina Aust, Industrial Master in Plastics and Rubber, Fraunhofer IGCV
“The collaboration with Fraunhofer IGCV is based on regular, open and constructive exchange. Since the start of the test series, the tests and analyses have been systematically optimized and refined. We are very grateful for the milestones achieved so far and look forward to future developments.”
Vitali Gerbershagen, Product Owner KAB3L®, Kube GmbH Ingenieurbüro
