Vehicle electrics

The electrical system is the nervous system of the automobile.
Increasingly sophisticated stability programs, navigation systems, and comfort features are causing the on-board electrical system to swell to many kilometers of cables. Added to this are complex electronics and dozens of control units. Every small car today has more electronics and electrical components on board than the module that landed man on the moon. This requires intelligent planning. Volke offers competent support in development – ​​including:

On-board network
Package
Concepts
Testing
Change management
BC³O Control office
Technical documentation

Electric  On-board network

On-board network

Volke develops complete electrical systems. The abbreviation VOBES stands for Volkswagen Electrical System Development System.
This process describes the development of the electrical system, from the design in CAD-E3D to the creation of the wiring diagram in EB Cable (Logical Cable) using data from the system wiring diagrams, and the creation of the wiring harness drawing in LDorado (drawing derivation), i.e., the merging of design and electrology (electronics).
In this way, Volke creates complete and DMU-capable wiring harnesses virtually, without the need for countless sample wiring harnesses that need to be adapted. Thanks to seamless data reproducibility, all design changes to the environment—such as the body, interior, and engine—can be implemented quickly and flexibly, even on-site at the customer's premises if desired. In each case, a seamless development process from concept to series production is possible. In addition to the software and hardware solutions mentioned above, project proximity and integration into the development of the entire vehicle are Volke's key competitive advantages.

Electric   Package

Electric - Package

By the electrical package, we mean the structural design of all electrical components, taking into account and roughly dimensioning the wiring harness. This includes cable guides, battery consoles, sheet metal holders, speaker sealing rings, and the positioning of control units, sensors, speakers, switches, and their mountings. From design to production prototype, the customer receives everything from a single source – quickly and reliably: Volke creates initial drafts, conducts installation space analyses, and creates dummies in CAD. In close collaboration with the customer (the automotive industry and its development suppliers), Volke builds 1:1 functional prototypes in sheet metal or plastic. Volke also handles all documentation.

Electric   Concept development

Concept development

Prototypes are required for many installations and investigations in order to be able to demonstrate and test new functions in the vehicle.

  • Build of sample cable harnesses
  • Concepts for mounting electrical components in vehicles (3D printing, mounting production)
  • Design of wiper concepts

Electric   Testing

Testing

  • Testing vehicle requirements:
    Equipping prototypes and endurance vehicles with measurement points for component tests (e.g., material tests)
  • Testing requirements on the test bench:
    e.g., wiring harness: electrical and mechanical testing (robustness of wires with respect to engine movement, temperature, etc.)
  • Endurance tests for components acceleration tests
  • Error recording and analysis, error detection and documentation.
  • Determination of causes (e.g. manufacturing defects, serial defects, assembly defects or equipment defects)
  • Simulator as a training tool:
    Train and learn how to handle live parts

Electric   Change management

Change management

Change management is the standard corporate process for managing product change scopes.
It encompasses the evaluation, approval, and implementation of product change scopes that impact technology, costs, quality, and schedules.
Change management controls changes to parts and scopes in vehicles and assemblies.
In the product process, change management is positioned between CSC allocation or P release and EOP (End of Production).

  • Change control (ÄKO)
  • Deviation permit (AE)
  • Amendments (ÄA)
  • Model update (MP) (LCP)

Electric   BC³O Control office

BC³O Control office

  • Competence:
    Analysis of development content using a checklist for new product launches and model updates, participation in interface committees, and support in the creation of development standards
  • Controlling:
    Analysis of problem cases, adherence to valid guidelines, and active support for future compliance. Design of temporary interim solutions/recommendations for existing process gaps (construction sites)
  • Coatching:
    Development of training concepts / employee training EKE (e.g. English training, training of new employees Contact person for internal and external project members

Electric   Technical documentation

Technical documentation

  • PDM creation:
    PDM (Product Detailed Assembly Instructions) are created at different product maturity levels in the VMP (Virtual Assembly Process) system and, in a few exceptions, in Excel. Creation or modification is initiated by the BTV of the respective component.
  • TLD creation:
    TLD (Technical Guideline Documentation)
    Proof of compliance with the minimum legal requirements to achieve uniform, legally coordinated documentation of individual components. The scope of the current and planned documents includes the documentation features for all new developments.
  • Creation of presentations / illustrations