Imagine being tasked with designing the human nervous system from scratch – a network of around 100,000 kilometers of nerves that must precisely connect the brain to every limb, organ, and cell in the body. Over 86 billion neurons form countless connections that must work in perfect harmony. Every impulse, every connection must be engineered so the body can move, feel, think, and react in milliseconds.
Now imagine doing it all without being able to test your solution before it goes live.
Designing the human nervous system without simulations sounds like a recipe for disaster. The same applies to modern vehicles — complex electrical systems powering autonomous features, advanced electronics, and safety systems require precise planning.
Simulations allow engineers to elevate the wiring system design process to a completely new level — eliminating risks that could compromise the vehicle’s “nervous system”, while increasing efficiency and precision.
Error and Cost Reduction – Why Simulations Are Essential
Modern vehicles are complex machines equipped with sophisticated electronics, autonomous systems, and multiple safety layers. All these innovations rely on a precisely designed network of wires and harnesses, acting as the nervous system of the vehicle.
Decades ago, these systems were designed based on the engineer’s experience and manual prototyping. Today, under constant pressure for speed and cost, traditional methods are no longer sufficient.
Simulations bring an entirely new quality to wiring system development. Engineers can now design and optimize in a virtual environment, minimizing error risk and speeding up development. With simulations, they can test different configurations, analyze stress points, identify potential collisions, and optimize packaging — long before a physical prototype is built.
Data Integration and Automated Design Validation
At VOITAS Engineering, we develop advanced internal software tools to support simulation and verification in the wiring design process. These solutions integrate data from multiple sources, automate analysis steps, and significantly reduce early-stage design errors.
With these tools, we can:
• Detect potential issues early — from EMC compatibility to stress points that could cause damage to harnesses
• Ensure data accuracy and consistency — integrating technical data and 3D construction files into a unified environment
• Save time and resources — through standardized processes and kinematic simulation under realistic conditions
Our in-house tools improve engineering efficiency and help adapt designs to specific client requirements — a must in today’s fast-changing automotive landscape.
IPS Simulation – Collision Analysis, Stress Validation and Space Optimization
One of the most powerful external solutions we use is IPS Simulation, which allows precise modeling of movable components, including wires and harnesses — even those inside corrugated tubes or protective sleeves.
This tool enables our engineers to:
• Visualize wire movement in a 3D environment for fast review and refinement
• Analyze stress, bending radius, and collision points to ensure durability and reliability
• Optimize packaging in tight vehicle spaces, which is crucial in modern, compact designs
Our experience with IPS Simulation has proven we can deliver fully validated wiring designs long before production starts — saving time, costs, and improving overall solution quality.
Virtual Prototyping as Engineering Foundation
At VOITAS Engineering, simulation and analytical software tools are not just support — they are the foundation of modern engineering thinking. Our internal tool development allows us to predict issues, eliminate errors at early design stages, and provide solutions that meet the highest standards.
In a world of electrification, automation, and increasing system complexity, simulation is no longer optional — it’s an essential part of every engineering project. It’s how we build the “nervous system” of the vehicle — precisely, reliably, and fully aligned with customer expectations.
