MK Seats GmbH  

Task:

The client requested verification of a regional train driver’s seat to ensure compliance with VDI 2230 guidelines for bolted joints, taking into account the loads defined by VDV 152. Additionally, the task included optimisation of the bolted joints for strength in case the criteria were not met.

Solution:

An advanced FEA model of the seat was developed, including a detailed representation of the bolted joints. A comprehensive strength analysis of the structure and joints was performed in accordance with relevant industry standards. In close collaboration between the MK Seats team and ENDEGO CAE experts, the bolted joints were optimised, ensuring full compliance with strength and technological requirements.

Result:

The outcome was an optimised and validated driver’s seat design, guaranteeing safe and reliable operation for many years. This enabled the client to expand its portfolio with more complex solutions for the railway sector and strengthen relationships with a key OEM.

In modern automotive engineering, cable routing and harness wiring play a crucial role in ensuring the reliable operation of electrical systems in vehicles. These components are subjected to continuous vibrations, dynamic loads with mechanical stresses, which can lead to premature failures if the cable routings are not properly designed.

At Endego, we specialize in strength design and use advanced Computer-Aided Engineering (CAE) simulations to validate and optimize vehicle components. In a recent collaboration with a Client, Endego CAE virtual validation team conducted a vibration analysis and strength optimization of automotive cable routing, to ensure compliance with requirements of a leading car manufacturer.

Project challenge: meet vibration and strength requirements

The Client sought to verify the structural integrity and vibration resistance of cable routing in a passenger vehicle. The key objectives included:

• Assess stress levels in the harness wiring under operational vibrations.
• Ensure compliance with the OEM’s durability requirements.
• Optimize cable routing to enhance structural strength and minimize vibration-induced fatigue failure risk.

Given the complexity of modern automotive wiring systems, the challenge was to validate the fixation points, optimize routing paths, and enhance overall vibration resistance while maintaining ease of assembly.

Our approach: make advanced FE vibration simulations and consider values of sophisticated parameters

To meet the Client’s requirements, strength specialists at Endego, named also CAE virtual validation team, developed a high-precision Finite Element model of the cable routing system.

Key steps in the analysis:

1. Creation of a detailed FE model:
   • a computational model of the cable routing was developed in three dimensions; material properties, structural constraints, and fixation points were incorporated.
   • the attachment points were carefully modelled to capture real-world mounting conditions and cable movements.
2. Analiza wibracyjna z zastosowaniem obliczeń typu PSD:
   • power Spectral Density (PSD) vibration simulations were performed to assess how the cable routing behaves under realistic driving conditions.
   • the frequency response of the structure was analyzed to identify critical resonance zones where failure risk increases.
3. Calculation of RMS Stress Values:
   • the Root Mean Square (RMS) stress distribution was calculated across the required frequency range, identifying stress concentrations and potential fatigue failure points.
   • the results helped predict long-term durability and indicated areas for structural improvement.
4. Optimization of cable routing:
   • working closely with the Client’s engineering team, Endego specialists refined routing paths, fixation placements, and vibration-damping strategies to enhance durability.
   • the final design minimized excessive stress levels, reducing the risk of cable fatigue and failures over time.

Through simulation driven design improvements, the cable routing achieved optimal vibration resistance while meeting OEM’s specifications.

Project outcome: Reliable and Scalable Automotive Cable Routing

The optimized cable routing design, as validated by Endego CAE virtual validation engineers, ensure long-term durability and compliance with automotive industry standards.

The key benefits for the Client include:

• Reliable and vibration-resistant cable routing reduces the risk of electrical failures.
• Full compliance with the OEM’s strength and vibration requirements.
• Increased production of complex harness wiring support the growing demand in the automotive sector.
• Strengthened collaboration with a major car manufacturer, expanding business opportunities.

By leveraging FEM analysis and vibration optimization, Endego helped the Client to achieve robust and failure-free wiring system thus, enhancing vehicle reliability and safety.

At Endego, we offer structural analysis based on CAE simulations for automotive, rail and industrial applications. Endego expertise in advanced vibration analysis, fatigue strength assessment, and dynamic load simulations help manufacturers build more durable and efficient vehicle components.

If your company is looking for engineering support in harness wiring design, vibration validation, or dynamic stress analysis, contact us today! Our team is ready to help you optimize your automotive components for maximum reliability.

Get in touch with us to discuss your project.

In the railway industry, structural integrity and compliance, together with rigorous safety standards, are essential to ensuring the durability, reliability, and safety of passenger train components. With increasing demands for lighter, stronger, and more efficient designs, manufacturers need advanced engineering solutions to adjust, validate, and optimize their products.

At Endego, we specialize in analysis, assessment and structural optimization of railway components involving the Finite Element Method (FEM). In a recent collaboration with a Client, Endego’s team conducted a comprehensive strength analysis and optimization of the internal ceiling and monitor gondola structure for a regional passenger train, and ensured full compliance with railway engineering standards.

Project challenge: compliance with stringent railway standards

The Client sought an in-depth structural assessment of:

• the internal ceiling structure including its mounting system;
• the ceiling-mounted gondolas for monitors.

These components had to meet the requirements of the EN 12663-1 standard which is a crucial railway vehicle standard governing structural integrity under static and dynamic loads, during regular operation and at exceptional events. Additionally, welded and bolted connections had to comply with the following standards and guidelines:

• DVS 1612 and DVS 1608 (fatigue strength of welded connections for railway applications)
• VDI 2230 (bolted connections and joint optimization)

In cases when after primary check the structures failed to meet these strength and durability criteria, the Endego team was tasked to optimize their structure while ensuring ease of manufacturing and cost-effectiveness.

Our approach: advanced engineering simulations & structural optimization

To meet the Client’s requirements, Endego CAE virtual validation team applied high-precision Finite Element Analyses (FEA) and fine modelling techniques for connection joints.

Key steps in the analysis:

1. Creation of detailed FE models:
   • A computational model of the ceiling assembly and monitor gondolas was developed which incorporated material properties, structural geometry, and loading conditions.
   • The welded and bolted joints were modelled using realistic constraints to simulate actual operating conditions accurately.
2. Strength and compliance assessment:
   • The structures were analyzed under real-world operational loads, including vibrations, fatigue stresses, and static loads.
   • Failure modes such as excessive deformation, stress concentration, and connection weakness were evaluated to determine whether the structures meet the requirements of the EN 12663-1 standard and of the other relevant guidelines.
3. Structural optimization:
   • Working closely with Client’s engineering team, Endego specialists optimized the structural parameters and joint configurations to enhance strength while maintaining manufacturability.
   • Material thickness, reinforcement placements, and fastener selections were refined to improve durability without excessive weight increase.

Through simulation driven optimization, the train’s ceiling and monitor gondola structures were successfully modified and adapted to achieve full compliance with railway industry standards.

Project outcome: Reliable, Compliant, and Scalable Train Components

The strength-optimized ceiling and gondola structures, as verified by Endego engineering team, ensure safe and failure-free operation for years to come. The key benefits for the Client include:

• Fully compliant railway components, meet the strict European requirements.
• Enhanced structural integrity to withstand long-term operational stresses and vibrations.
• Increased production capacity for complex railway components, supporting business expansion.
• Strengthened partnerships with major passenger train manufacturers, reinforcing the Client’s industry position.

By providing CAE analysis, Endego helped the Client streamline design validation, optimize structural performance, and reduce risks for manufacturing and assembling defects.

At Endego, we offer structural optimization, engineering simulation, and compliance verification for railway, automotive, and industrial applications. Our expertise in FE modelling, welded connection analysis and fatigue strength assessment helps manufacturers enhance product safety, durability and cost efficiency.

If your company is looking for engineering support in railway vehicle design, structural integrity assessment, or component optimization, contact us today! Our team is ready to help you achieve the highest standards of performance and safety in your projects.

Get in touch with us to discuss your Project.

Project challenge: find the best compromise between strength and stiffness under the limited mass weight of the components

The client requested a structural assessment of key components used in mobile assembly lines:

• grippers,
• adapters,
• consoles,
• carriages for the transport of car bodies and assemblies.

These elements are subjected to high accelerations and mechanical stresses, and deformations, which can affect either their durability or operational efficiency. The challenge was twofold:

1. Assess whether the components could withstand the required stresses under dynamic loads.
2. Optimize their design in cases where the strength or deformation criteria are not met, and so provide improved reliability without unnecessary mass weight increase.

The goal was to enhance operational safety, extend component lifespan, and optimize manufacturing precision.

Our approach: advanced FE simulations & structural optimization

To meet the Client’s requirements, the Endego CAE Virtual Validation team applied the analysis by the Finite Element Method (FEM) to evaluate and optimize the mobile assembly line components.

Key steps in the analysis:

1. Creation of FE models for individual components and sometimes MBD models:
   • Each gripper, adapter, console, and carriage was modeled based on geometry, with detailed material properties and connection representations.
   • Bolted and welded joints were depicted to capture their behavior under real-world conditions.
2. Stress distribution and deformation assessment:
   • The simulation models were subjected to operational acceleration patterns and mechanical forces to determine stress distribution, deformations, and potential failure locations.
   • Connection joints and mounting points were assessed to ensure structural integrity during long-term operation.
3. Component optimization:
   • In collaboration with the Client’s engineering team, Endego strength specialists identified areas requiring reinforcement or redesign.
   • The optimized component structures maintain strength, durability, and working precision while ensuring technological feasibility and ease of manufacturing.

By utilizing simulation-driven design validation, Endego ensured that all components meet stringent safety standards while maintaining optimal performance.

Project Outcome: Safe and Reliable Components for Mobile Assembly Lines

The strength-optimized components, as analyzed and verified by the Endego engineering team, provide long-term durability and failure-free operation.

The key benefits for the Client include:

• Increased production capacity for mobile assembly lines in the automotive sector.
• Improved reliability and safety of key manufacturing components.
• Expanded cooperation with a major automotive manufacturer and strengthened position in the industry.

By ensuring that all grippers, adapters, consoles, and carriages meet the required stress and deformation criteria, Endego helped the Client to enhance production efficiency, minimize maintenance downtime, and ensure consistent manufacturing quality.

At Endego, we provide structural optimization by CAE virtual validation services for automotive manufacturing, industrial automation, and mechanical engineering applications. Our expertise in FE modeling, stress analysis, and dynamic load simulations enables manufacturers to build robust, efficient, and scalable production systems.

If your company is looking for engineering support in structural validation, dynamic load assessment, or component optimization, contact us today! Our team is ready to help you enhance manufacturing reliability and performance.

Get in touch with us to discuss your project.

Project challenge: evaluate battery strength under swelling cell pressure

The Client approached Endego with a key concern: evaluate the structural strength of an aluminum battery frame subjected to pressure from swelling battery cells and determine the forces acting on the battery box mounting points.

Battery cells expand and contract during charge and discharge cycles, and generate internal stresses that can affect the integrity of the battery frame. The purpose of the task was to:

• Assess the stress and deformation behavior of the aluminum frame under swelling load.
• Determine the forces at the mounting points and ensure proper load distribution.
• Verify the overall structural stability of the battery housing over extended time, with operational cycles.

Given the nonlinear behavior of materials used for battery housings, a precise and detailed simulation by the Finite Element Method (FEM) was required to capture real-world performance and optimize the design accordingly.

Our approach: advanced FE simulations & structural analyses

To address the Client’s requirements, the Endego CAE Virtual Validation team developed a high-fidelity FE model of the battery frame, which accurately represents its connections, material properties, and loading conditions.

Key steps in the analysis:

1. Nonlinear FE model creation:
   • A detailed simulation model of the aluminum battery frame was developed.
   • Nonlinear material properties have been applied for realistic stress-strain behavior modelling under thermal loads.
2. Assessment of stress and deformation states:
   • The model was subjected to internal pressure from swelling battery cells. The resulting stress distribution, deformation levels, and failure risks have been analyzed.
   • Stress concentration locations had been identified. Design improvements have taken them into account to mitigate the risks of such potential weak points.
3. Evaluation of forces at battery box mounting points
   • Together with the Client’s team, Endego engineers have precisely determined forces in the mounting points.
   • Then, the mounting system design was optimized for enhanced structural reliability.

This multi-faceted approach ensured that the battery frame design would withstand operational stresses while maintaining lightweight efficiency, a crucial factor in EV battery development.

Project outcome: reliable and scalable battery frame design

The optimized battery frame, as analyzed and verified by Endego engineering team, provides long-term safety and failure-free operation. The key benefits for the Client include:

• Reliable and durable battery housing that ensures safe operation over multiple charging cycles.
• Expansion of the range of large-format batteries was made possible; production of more complex battery structures was now enabled.
• Partnership growing with leading EV manufacturers; the Client’s position in the electric vehicle market was established.

Endego leveraged virtual validation and helped the Client enhance battery frame reliability, reduce development risks, and meet stringent safety regulations.

At Endego, we specialize in structural, thermal, dynamic, and nonlinear analysis for battery systems, electric vehicles, and lightweight structures. Our expertise in FE modeling, CAE virtual validation, and material optimization helps manufacturers build safer and more efficient energy storage devices.

If your company is looking for engineering support in battery pack design, lightweight material analysis, or structural integrity assessments, contact us today! Our team is ready to help you develop next-generation battery systems that drive innovation in EV technology.

Get in touch with us to discuss your Project.

The Client approached Endego with a specific request: to analyze the strength and durability of multiple structural and mechanical components of pickup trucks under real-world operating conditions. The key focus areas included:

• main frame with cargo box,
• cover and roof of the cargo box,
• roof rack,
• test frame,
• bolted connections.

Each of these components had to withstand vibrations and dynamic driving loads, like accelerations. Additionally, where the strength criteria were not met, Endego task was to optimize the design and to improve the static and dynamic performance while providing manufacturability on a high level.

Our approach: advanced engineering simulations & FE analyses

To meet the Client’s expectations, the Endego Virtual Validation team applied Finite Element analyses to evaluate and optimize the pickup truck’s structural components.

Key steps in the analysis:

1. Creation of detailed FE Models:
   • each component was modeled individually, including its material properties, loading conditions, and interaction with other parts.
   • the bolted connections were precisely depicted to capture their real behavior under dynamic road conditions.
2. Static strength and vibration dynamics calculations:
   • static load cases were defined to determine stress distribution and deformation under typical operational loads.
   • vibration behavior was analyzed, with natural frequencies in focus and their Effective Mass Participation (EMP) to predict high energy resonance ranges.
3. Optimization of structural properties:
   • collaboration with the Customer’s team enabled Endego to refine bolted connections, stiffness distribution, and dynamic performance features.
   • the optimization process had reduced stress concentrations in focus while providing high technological feasibility.

By leveraging expertise in CAE-driven design, Endego ensured that all components meet strength and durability standards and requirements, and exhibit reduced failure risk, and avoid costly redesign.

Project outcome: reliable and light weight pickup components

The parts and assemblies designed and optimized by Endego engineers exceed industry requirements and were validated for long-term reliability. The key benefits for the Client included:

• safe and failure-free operation of lightweight pickup truck components for years to come,
• significant expansion of production capacity for these components,
• enhanced cooperation with leading automotive OEMs, thanks to high product reliability.

Endego’s expertise in strength and reliability with tolls like FE analyses and CAE optimization has helped the Client to appear as a more confident and attractive partner within the automotive industry.

Partner with Endego for advanced engineering solutions with CAE tools

At Endego, we specialize in simulation-driven product development, helping automotive manufacturers enhance product durability, optimize design performance under minimum weight, and streamline production efficiency.

If your company is looking for engineering expertise in structural analysis, vibration optimization, and bolted and welded connection assessment, reach out to us today! Endego team of experts is ready to support your next automotive, rail, or industrial project with its best CAE solutions.

Contact us to discuss your Engineering Challenges

The Endego solution 

To address the customer’s challenges, we applied a methodical approach grounded in technical expertise and advanced tools: 

1. Ethernet stack configuration: we configured the Ethernet stack based on Basic Software (BSW) implementation. Leveraging design and development tools provided by Vector. 
2. Development of an ASIL-B software component (SWC): A new ASIL-B SWC was implemented to manage non-diagnostic communication, specifically for SomeIp signals supervision. This software component was designed to enhance the reliability of signal processing in the system. 
3. Creation of a Complex Device Driver (CDD): Endego delivered a new CDD tailored to provide diagnostic features for the Ethernet transceiver and stack. This solution ensures seamless functionality and simplifies troubleshooting during system operation. 
4. Securing HPC: Communication security was achieved by configuring the HSM. This guarantees data integrity and protection against cyber threats, a critical aspect for modern connected vehicles. 
5. Optimization of Ethernet communication: Traffic shapers were configured and verified to optimize Ethernet communication performance. This ensures efficient bandwidth utilization and minimizes latency, enhancing the overall system responsiveness. 

Key technologies and tools 

Endego’s solution was made possible through a combination of advanced technologies and tools, including: 

• Programming Languages: C, CAPL, MiL 
• Technologies:: Vector tools, HSM, Infineon Tasking Toolset, AUTOSAR, MATLAB/Simulink 
• Hardware: Aurix TriCore TC377X processors 

Impact and value delivered 

Through our comprehensive approach, we successfully addressed the Tier 1 customer’s requirements, delivering an efficient and secure solution for HPC and the corresponding ADAS partition. The implementation of diagnostic features, secure communication protocols, and optimized Ethernet performance highlights Endego’s capability to tackle the complexities of modern automotive systems. 

This project highlights our expertise in automotive software and hardware development while reflecting our dedication to providing innovative and high-quality solutions for advanced vehicle technologies. 

For more insights into our projects and expertise, visit our blog or connect with us to discuss your engineering challenges. 

The US start-up developing its electric 3-wheel vehicle needed to establish a new harness development process that integrated seamlessly with other development areas. The harnesses required to cover both high-voltage (HV) and low-voltage (LV) areas ((incl. CAN/LIN data transmission), emphasising using available components in the US market and designing new elements to optimise future production costs.

Solution: Endego’s integrated approach

Endego deployed an entire harness development team, sending a resident engineer to the USA to streamline communication and real-time problem-solving. Our team leveraged years of experience to integrate the necessary design tools and develop additional components. In collaboration with our CAE department, we conducted dynamic and thermal simulations of the harnesses, adhering to US market design standards. We also adapted European component databases to meet US requirements, ensuring seamless integration and cost efficiency.

Key elements of our solution included:

• Full Wire Harness Development Team: Endego provided a dedicated team with extensive experience working with European OEMs, systems, processes, and standards.
• Resident Engineer in the US: A resident engineer was sent to the United States to facilitate close collaboration with the client, ensuring smooth communication and real-time issue resolution.
• Tools Integration for Harness Development: Endego integrates specialised tools for designing and developing wire harnesses.
• Design of HV and LV Harnesses: The team developed complete High-Voltage (HV) and Low-Voltage (LV) harnesses, including data transmission via CAN/LIN protocols.
• Dynamic and Thermal Simulations: Endego conducted dynamic and thermal simulations that complied with US market standards.
• Component Database Adaptation: The European component databases were adjusted to meet the requirements of the US market.
• Compliance with Functional Safety Standards: The team ensured compliance with ISO 26262 Functional Safety standards and adapted them to the US-specific conditions and components.
• Project Timeliness: The client was able to complete the project within the expected deadlines thanks to the efficiency and collaboration provided by the Endego team.

Technologies: Advanced tools and expertise

Our solution utilised a range of advanced technologies and methodologies:

• Functional Safety (FUSA): Incorporating functional safety principles to meet rigorous safety standards.
• High Voltage (HV) and Low Voltage (LV): Expertise in designing both HV and LV harnesses.
• VeSys and NX Routing Electrical: Leveraging these tools for precise and efficient electrical system design.
• LDorado: Employing LDorado for advanced development of production drawings.
• Communication protocols: Integrating CAN and LIN protocols for reliable communication within the vehicle.

Expectations and standards for complete car development:

• Tool integration: Increasing reliance on integrating multiple design tools for streamlined workflows.
• On-site engineering support: Growing need for on-site engineering support to facilitate real-time problem-solving and adaptation.
• Functional safety: Emphasis on incorporating functional safety principles to meet stringent safety standards.
• Component cost efficiency: Focus on using existing market parts to reduce costs and streamline production.
• Comprehensive simulation: Utilization of dynamic and thermal simulations to validate designs and ensure compliance with standards.

Endego’s competences

Endego’s harness design and development competences are extensive, covering every aspect from initial electrical diagrams to final production. Our capabilities include:

• Process expertise: Assisting clients in implementing specific development processes to streamline project execution.
• Production implementation: Implementing products into production efficiently to ensure seamless integration and high quality.
• Electrical diagrams: Creating electrical diagrams that serve as the blueprint for harness designs.
• Packaging.
• 3D models and 2D drawings: Developing 3D models and 2D manufacturing drawings.
• Component design: Designing and optimising individual components.
• Simulations.
• FuSa.

For more detailed insights into our competencies, visit our Wiring Harness page.

Endego’s recent project with a US startup highlights our ability to overcome complex design challenges and deliver expert harness development solutions. By leveraging cutting-edge technologies and our extensive expertise, we successfully helped our client bring their electric 3-wheel vehicle to market on time.

For inquiries or more information about our services, feel free to contact us.

A TIER1 supplier, commissioned by a renowned OEM to develop a complete vehicle from the concept phase, including developing electrical harnesses according to the VOBES process and complying with OEM standards (VW6000, VW80000). This required considering the feasibility and optimization of the production process for individual harnesses, their assembly into a complete product, and the potential for installation in a vehicle still in the early stages of development, while also maintaining the required quality, minimizing unit production costs, and ensuring parts were not susceptible to changes in later project stages.

Solution: Endego’s integrated team and advanced simulations

Endego assembled a specialised team to address these challenges. Our approach included:

• Specialized teams: the team developed HV and LV harnesses, ensuring compliance with VW6000 and VW80000 standards and optimizing production costs.
• Project Management: we provided a Project Manager along with a team to manage the project, embracing the ASPICE and VOBES processes.
• Simulations: using IPS, our team conducted thermal and durability simulations, virtual tests, and dynamic harness simulations.
• Cross-department communication: to ensure proper packaging, we managed synchronization with the client’s Body-In-White, Interior, and Exterior departments.
• EMC testing: the concept was checked for EMC compliance to prevent electromagnetic interference.
• Compliance: adhering to the VOBES process and conducting ISO26262 Functional Safety analyses.

Technologies: Leveraging multiple tools

Our solution utilised advanced technologies and methodologies:

• EB Cable and LDorado: For detailed harness design
• CATIA EHI and ELENA: For 3D routing design and integration.
• Teamcenter and Architect: For project management and documentation.
• Functional Safety (FuSa): Incorporating safety principles to meet rigorous standards.
• IPS and ASPICE: For simulations and adherence to process standards.

Expectations and standards for complete car development:

• Stringent compliance: There is an increasing need to adhere to specific standards and processes.
• Advanced simulations: Growing reliance on simulations for design validation and performance testing.
• Cross-department collaboration: Emphasis on seamless communication between different vehicle development departments.
• Functional safety: Incorporating comprehensive safety analyses to meet industry standards.
• Cost efficiency: Focus on maintaining high quality while minimising production costs.

Endego’s competences

Endego’s competences in vehicle harness design and development are extensive. Our capabilities include:

• Process expertise: Assisting clients in implementing specific development processes to streamline project execution.
• Production implementation: Implementing products into production efficiently to ensure seamless integration and high quality.
• Electrical diagrams: Creating electrical diagrams that serve as the blueprint for harness designs.
• Packaging
• 3D models and 2D drawings: Developing 3D models and 2D manufacturing drawings .
• Component design: Designing and optimizing individual components.
• Simulations
• FuSa

For more detailed insights into our competencies, visit our Wiring Harness page.

Endego’s recent project with a TIER1 supplier showcases our ability to meet complex requirements and deliver successful outcomes. By leveraging advanced technologies and our extensive expertise, we ensured the project adhered to stringent standards and was completed on time.

For inquiries or more information about our services, don’t hesitate to get in touch with us.