Wiring Harness Design
PREEvision Use Case

PREEvision – Model-Based Design and Development of the Wiring Harness

PREEvision Wiring Harness Design and Development
Optimal connections right from the start.

As the most expensive and heaviest single part of an E/E architecture, the wiring harness offers enormous potential for optimization and cost savings.

PREEvision supports development engineers in finding cost-optimized designs and working out all the details.


  • Consistency from initial design to production order
  • Precise representation of model data
  • Easy exchange of designs and geometry data via KBL
  • Automation such as wiring harness router and ground spot optimization
  • Automatic calculation of cable lengths, weight, costs etc.
  • Easy creation of diagrams, including plugs and pin assignments

The Use Case

PREEvision helps wiring harness engineers to find cost-effective wire and cable assembly designs by providing multiple modeling layers with dedicated tables and diagrams.

PREEvision Wiring Harness Diagram
The PREEvision wiring harness diagram is based on the linked model data and thus enables the highlighting of individual connections.

To be able to compare alternatives, optimize the design and ultimately develop the wiring harness in detail, PREEvision provides modeling layers for the electric circuit diagram and wiring harness, as well as special tools such as a wiring harness router and automated power calculation. Suitable import and export functions are also included.

Functions / Features

Hardware Network Topology

PREEvision Hardware Network Topology
Hardware topology: Modeling hardware components and their connections.

The PREEvision hardware topology layer supports two aspects of hardware modeling: First the definition of the hardware components such as electronic control units, sensors and actuators. And second the definition of the logical connections between the hardware components and their networking.

Electric Circuit Diagram

PREEvision Electric Circuit Diagram
Circuit diagram: Refinement of component connections with power supply, ground and currents.

In the electric circuit diagram, hardware components and their connections are refined through the description of the electrical characteristics and the definition of the power supply and ground.

Integrated circuit synthesis automatically generates schematic connections and spares the developer from having to carry out error-prone activities. PREEvision provides hardware modules and components such as fuses and resistors for modeling the internal electrical design of components.

The power calculation of PREEvision determines the static power consumption of a component network in various different operating states. The required diameter and materials for cables and pins, for example, can be determined based on this.

Wiring Harness

PREEvision Wiring Harness Diagram
Wiring harness diagram: Refinement of connections in physical wires, leads, plugs and splices.

Based on a given electric circuit diagram, PREEvision’s circuit synthesis can automatically create a wiring harness diagram with wiring harness connections and pins.

The wiring harness can be defined in detail including wire connections, connectors, splices, isolation points, pins and harness furniture.

A wire or cable represents a piece of hardware with all its physical properties as well as costs among other things. Copper wires, aluminum wires and optical wires may all be modeled.

Vehicle Geometry

PREEvision Vehicle Geometry
The vehicle geometry can be imported from a 3D KBL file to PREEvision.

The vehicle geometry is is needed to evaluate and optimize the final wiring harness. It describes possible installation locations for components and possible routing paths for cables and wires.

Based on the imported 3D data, PREEvision creates a geometry diagram automatically. A wiring harness router calculates the most favorable routing path.

Data Exchange

PREEvision provides different final work products for the serial production of the wiring harness:

  • Wiring Harness Diagram
    Typical harness diagram as PDF or image file including connector locations. This diagram shows the wiring connectors at the end of the segments including detailed pinning information.
  • KBL Files
    PREEvision supports the VDA exchange format KBL ("Kabelbaumliste", meaning: "Harness Description List") for import and export of harness design data and specifications in 2D as well as 3D formats.
  • Reports
    Additional data needed for smooth collaboration between OEM and suppliers can be provided via reports. The predefined report templates can be easily modified and adapted to specific needs.
PREEvision Wiring Harness Diagram
Typical wiring harness diagram as PDF or image file including connector locations.

Features and Utilities

Assistance and benefits from various PREEvision functions:

  • Consistency Checks
    Automatic and editable checks help to develop a consistent model.
  • Reuse
    Reuse of single components or bigger parts of the model to minimize redundant work.
  • Metrics
    PREEvision’s inbuilt scripting environment with full read/write capability in the data model allows customers to develop their own analyses using the data contained in their model and also allows customers to automate, and thereby streamline, their modeling process.
  • Version Management
    Reuse and further development of parts from previous projects as new revisions or part of a new branch.
  • Change Management and Lifecycles
    The integrated change management provides functions for assuring controlled and structured implementation of change requests. It supports efficient and consistent follow-up of change requests and errors for all development artifacts. PREEvision therefore supports the handling of tickets, including their linking to the technical artifacts. Life cycles in PREEvision enable management of work flows that is tuned to the specific organization.
  • Product Line and Variant Management
    Development of a 150% model including all available functions and their corresponding components. Different product variants are tailored and managed as subsets.
  • Table Editors
    Define and easily set up tables and table editors to represent exactly the data needed for a specific task.


Technical Articles

PREEvision Wiring Harness Design and Development

Controlling Complexity in the Vehicle Wiring System

Model-based wiring harness development

Handwritten corrections on printouts, giant spreadsheets, and countless tool changeovers: these and similar approaches are used in an effort to keep a handle on the development of a vehicle wiring system. More efficient approaches are needed to control the complexity of modern electrical distribution systems in the long run. The model-based development methods already in successful use in many industrial sectors provide the needed tool for this.

Translation of a German publication in "Elektronik automotive", special issue S4/2016 "Bordnetz"


Model-Based E/E Development with PREEvision

From Architecture Design to Series Production

PREEvision offers a comprehensive modeling language to describe all aspects of e/e systems. All engineers involved in the development process find tailored diagrams and editors for their work. And all in one integrated tool. Based on a given geometry, wiring harness designers, for example, define the complete wiring harness including all details like pins, connectors, wires, cables and splices.

Playing time 4:00 minutes, published 3/2018

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