The design phase is critical in the manufacturing process, as the slightest inaccuracy can negatively impact the end product and the reputation of the manufacturers. Virtual Interconnect, a specialist in routed systems solutions, has set the mission to make the design process faster and more efficient with cutting-edge software solutions. The company’s extensive experience in harness design, coupled with over 125 years of combined engineering know-how in numerous market sectors, including automotive, aerospace, and industrial equipment, has enabled it to become the go-to partner for diverse client requirements. Virtual Interconnect has also earned the tag of PTC Gold Technology Partner.

For companies going to implement PTC tools or willing to improve their processes, Virtual Interconnect acts as a subject matter expert. They conduct workshops to understand clients’ existing processes as well as to identify and analyze the market gap and the functionality of the tools. Virtual Interconnect then addresses these requirements by offering customized solutions.

For example, the company provides Harness Manufacturing Extension (HMX) within PTC solutions to provide an automated design process for manufacturing documentation while reducing errors. The bespoke software extensions bridge the gap between your specific needs and the out-of-the-box functionality of Creo Schematics and Creo Piping and Cabling Extension (PCX).

Virtual Interconnect understands that the knowledge of voltage drop across conductors is crucial in the harness design process. To this end, it has developed eSimulate, an electrical network analyzer to help clients perform functional simulations. eSimulate allows Virtual Interconnect’s customers to determine the inrush current and perform static analysis while minimizing the copper weight (if needed).

Virtual Interconnect has the ability to conduct full dynamic simulations where the circuits can be pulsed. By switching the circuit on, the inrush current drawn by the circuit can be visualized. This is a crucial step toward solving issues like wire overheating or a component being overstressed.

Identifying issues such as resistors dissipating more power than they are rated for, or switches sustaining higher voltages than their maximum limits allowing engineers to rectify the problem and design compliant products. Virtual Interconnect creates a complete 3D virtual prototype, including all mechanical and electrical components. This prototype provides manufacturers with a comprehensive understanding of the problems that might snowball into a major headache during the design stage. Simultaneously, many manufacturers consider CAD and harness modeling an intermittent activity. Virtual Interconnect conducts harness design every day of the week, making them much more efficient and accurate.

For instance, a company operating in North America, Asia, and Europe once approached Virtual Interconnect as they had to deploy approximately 14 chartered engineers to sign off the safety cases. Despite this, they lacked the flexibility to quickly accommodate design changes.

Evolving from a company that does basic harness design work, Virtual Interconnect has come a long way to devise engineering tools and libraries to make the design process efficient and accurate for customers

Virtual Interconnect was able to reduce calculation time, accommodate design changes, and streamline the process. This helped the customer considerably reduce the resources dedicated to the process, making it more cost-effective.

“Evolving from a company that does solely harness design work, Virtual Interconnect has come a long way to devise engineering tools and libraries to make the design process efficient and accurate for customers,” says Dr. Brian Gilhooley, CEO, Virtual Interconnect. “We are now transitioning into a product company as opposed to a service company. We, in fact, are all set to expand our solution portfolio by launching a brand new product called WNCBridge, which intefaces Creo Schematics with PTC’s Windchill.”

The biggest contributor to Virtual Interconnect’s success has been its team of efficient and professional engineers, who are always on their toes to bring the best to the table. The company has also been able to keep the future in the safe hands of the directors by avoiding any external investment to fuel this transition.