Andrew Mutch Having previously worked as an aircraft technician with HM Forces, Andy is one of our Professional Services Consultants and has been with EPLAN for 10 years. Part of Andy's role is to actively analyse customers processes, develop solution concepts and workflows for customer requirements. Andy is also our resident Harness expert! Mutch.a@eplan.co.uk Andrew Mutch auf LinkedIn

6/07/26

Parallel Engineering for Wiring Harnesses: BOMAG’s Digital Twin Strategy

Author: Andrew Mutch Time to read: minute minutes

What if you could cut development time without compromising precision? BOMAG is doing exactly that, by designing mechanical prototypes and electrotechnical wiring harnesses in parallel rather than sequentially. This shift isn’t just a process tweak; it’s a smarter, faster way to build the machines that keep road construction moving.

As a global manufacturer of equipment such as earth and asphalt rollers, BOMAG knows a thing or two about efficiency and when it comes to cable harness development, there’s little that catches the company off guard. Powered by Eplan’s Harness proD software, BOMAG is rethinking how wiring systems are designed, tested, and brought into production. Whether working on physical prototypes or digital twins for series manufacturing, BOMAG’s worldwide collaboration is unlocking new levels of speed and accuracy.

Create prototypes and wiring harnesses at the same time: 1000 individual cables, 2 kilometers in length per machine

A central challenge so far has been that the electrical design team could only begin producing cable harnesses once prototype manufacturing was nearly complete. Measurements were taken late in the process, and harnesses were then designed around an almost finished prototype making it both inefficient and time-consuming.

In an ideal world, these steps would run in parallel. But this is no small task when you consider the scale involved: a single asphalt roller can contain around 1,000 individual cables with a combined length of over two kilometres. On top of that, even an engine wiring harness alone requires around 200 different components.

"Our goal was to have the wiring harnesses on the laying board close to series production before the physical prototype was completed."

Sascha Michalski, Team Lead Electrical Engineering, BOMAG

In the meantime, however, Eplan Harness proD has made exactly this possible. A digital representation of the cable harnesses is used from the very start of prototype development and continues to support the entire production process. Material BOMs can be easily created and detailed wiring harnesses can be designed in 3D based on the CAD data of the mechanical prototype, including routing paths and fasteners. This allows the mechanical and electrical design to work in parallel.

The results from this are significant time savings, improved collaboration across teams, and clear, consistent specifications for everyone involved from day one.

30 new prototypes, 400 wiring harnesses per year

The cable harnesses prepared, built and tested in-house can now even be assembled by external service providers. This is how impressive goals can be met: This year alone, BOMAG is to build more than 30 new prototypes, with 300 to 400 new wiring harnesses that will be added to the 2,000 already existing ones or partially replace them.

BOMAG2

Digital twin: Eplan and BOMAG jointly push the turbo in series production

However, the software delivers more than just performance boosts in prototype construction. BOMAG is also accelerating its series production processes with Eplan. Designers benefit from the seamless integration between the Eplan circuit diagram and the 3D model.

In the background, a comprehensive database compiles the components required for the wiring harness, such as stop parts. Eplan Harness proD is used to create 3D models with important information for assembly. This is carried out by external service providers who systematically receive derived data from BOMAG. The wiring harnesses of the various series models are not individualized and contain as few part numbers as possible. This significantly simplifies production, but makes the design more complex – no problem with Eplan Harness proD.

The data is so precise, in fact, that BOMAG can have even complex wiring harnesses produced simultaneously by multiple partners:

"The garment manufacturer simply has to stick to the drawing, then he can't do anything wrong."

Thomas Seis BOMAG

Thomas Seis, Electrical Lead Engineer, BOMAG

Changes to an ongoing series can also be easily entered with Harness proD – without any haptic prototypes. Thanks to the 3D model, the designers know at all times whether there is enough space available for hoses and lines and can thus discuss with the mechanics on an equal footing.

30 Eplan users worldwide: all pulling together

BOMAG is headquartered in Boppard in the Hunsrück region, but has production sites worldwide, including in India, China, the USA and Italy. A total of around 30 Eplan users work at BOMAG, who can communicate seamlessly with each other with the help of the integrated software and standardised processes. New generations of machines are created in Boppard. In the other plants, they will then be adapted to local characteristics. With Eplan, employees worldwide have access to the data of a model with all engine variants and options on one platform, wherever it is produced. All designers can work on it live – on a server to which they have virtual access.

Conclusion

"A system by electricians for electricians"

Sascha Michalski, Team Lead Electrical Engineering, BOMAG

With Eplan Electric P8 and Harness proD, BOMAG has perfected its electrotechnical planning over the past 10 years. Real and digital postage types are created in parallel, and packaging for series production is enormously simplified thanks to the digital twin. The international team of over 30 Eplan users has access to the designs from the headquarters worldwide and pulls together in mechanical and electrical design – a real best practice! BOMAG3

FAQs

What is wiring harness design in heavy machinery?

Wiring harness design involves planning and organising cables, connectors, and components to ensure reliable electrical connections within machines such as asphalt rollers. It includes routing paths, fastening points, and component integration to support both functionality and durability.

What is Eplan Harness proD used for?

Eplan Harness proD is a specialised software solution for designing wiring harnesses in 3D. It allows engineers to create detailed harness layouts based on CAD data, including routing, lengths, and connection points.

How does Eplan integrate electrical schematics with 3D models?

Eplan connects circuit diagrams directly to mechanical CAD data, allowing wiring harness designs to be developed within the context of the machine layout. This ensures all components fit and function correctly from the start.

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