Introduction
The development of show vehicles follows different rules than series production, driven by different requirements and project goals. Tight schedules, evolving concepts, limited initial data, and the specific nature of such projects mean that some standard development processes simply cannot be applied. The approach must be more flexible, with fast and ongoing reactions to change. The system has to be designed quickly – but without creating chaos. Project management needs to remain structured, consistent, and aligned with real project needs. Despite the different priorities and working methods, the main objective remains the same: a reliable electrical system that fully meets the defined assumptions.
In this project, we designed and delivered a fully functional low-voltage electrical system for a show vehicle developed by a German mobility engineering company, including technical documentation, controller software, and the physical wiring harness – from initial concepts through installation and final testing.
Work scope
Our work included:
- Component mapping and connection logic
- Power and ground concepts
- Controller pinout definitions
- LV harness topology and schematics
- Selection of connectors and adapter cables to interface components, considering electrical and environmental requirements
- Inline connection strategy aligned with 3D packaging
- Production-ready documentation and supplier support
- Implementation on the vehicle
Due to the specific nature of the project and limited initial data, part of the work required additional activities such as direct measurements, and also ongoing alignment between 2D and 3D teams to keep the system consistent.
Results
- Complete low-voltage wiring harness designed from scratch
- Full technical documentation ready for production and implementation
- Manufactured harness delivered to the customer
- Successful installation and final system tests on the vehicle
Summary
This project shows how we handle full LV wiring responsibility in fast-moving, non-standard projects. By keeping close coordination between teams and staying flexible where needed, we delivered a working, well-documented system – ready to be built and installed, not just reviewed.