Assembly simulation of multi-branch cables

Cable assembly simulation is a key issue in the computer-aided design (CAD) of products with complex electrical components. In this study, an assembly simulation method is developed to simulate the assembly process of multi-branch cables. First, based on the Cosserat theory of elastic rods, a novel scheme is introduced to model the joints of multi-branch cables. The potential energy of joints is calculated by taking the topology and anatomical features into consideration. Various physical properties are considered. Various constraints, including connectors, collars, and handles are analyzed, based on which the initial conditions of assembly simulation are determined. The configuration of the cable is then calculated by minimizing its potential energy. To increase computational efficiency, GPU acceleration is introduced, which makes the simulation run at interactive rates even for a cable with resolution up to 1000 discrete points. Finally, the proposed algorithm is integrated into the commercial assembly simulation system, DELMIA. Several simulations were performed with our system. It was demonstrated that the proposed method is able to handle cables with complex topologies. In addition, the proposed method is about four times as efficient as a previous method, and it is able to generate realistic configurations of multi-branch cables at interactive rates. Thus, the proposed method is helpful in the assembly process planning of cables. (c) 2017 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.