Armored Cable Grounding Path Using Axial Outer Ground Conductor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing armored cables face challenges in maintaining consistent grounding performance due to intermittent contact between the second ground conductor and the interlocked armor, which compromises their effectiveness as a backup ground.
Innovation Solution
The armored cable assembly features a second ground conductor positioned outside the binder tape and aligned with the longitudinal axis, ensuring continuous contact with the interlocked armor at each helical convolution, with a periodic reversal of cable lay direction to enhance grounding efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the second ground conductor is positioned between the valleys of conductors within the binder tape, then the cable structure is compact, but the grounding performance is inconsistent due to intermittent contact with the interlocked armor
Solution Approach 1:
The second ground conductor is extracted from the conventional position between conductor valleys and relocated to the outer surface of the binder tape. This extraction allows the ground conductor to maintain consistent contact with the interlocked armor without being obscured by the conductor bundle geometry, thereby improving grounding reliability while simplifying the positioning requirement.
Solution Approach 2:
The second ground conductor is repositioned from a radial position (between conductor valleys) to an axial position (outer surface aligned with longitudinal axis). This dimensional change enables continuous contact with the helical armor convolutions throughout the cable length, ensuring consistent grounding performance.
2Reliability
If the second ground conductor is placed outside the binder tape aligned with the longitudinal axis, then continuous contact with interlocked armor is ensured, but the cable assembly complexity increases
Solution Approach 1:
The interlocked armor serves dual functions: mechanical protection of the cable and continuous grounding path. By positioning the second ground conductor on the outer surface aligned with the longitudinal axis, the armor's helical convolutions naturally provide continuous contact points, eliminating the need for additional grounding mechanisms and simplifying the overall assembly.
Solution Approach 2:
The helical interlocked armor structure inherently provides continuous contact points along its length. The second ground conductor positioned on the outer surface utilizes this self-provided grounding path without requiring external grounding components or complex assembly procedures, thereby improving reliability while maintaining simplicity.
3Manufacturing precision
If the cable uses traditional armor configuration, then the manufacturing process is simple, but the grounding contact consistency is poor
Solution Approach 1:
The second ground conductor is pre-positioned on the outer surface of the binder tape in alignment with the longitudinal axis before the armor application process. This preliminary positioning ensures that when the interlocked armor is applied, continuous contact points are automatically established at each helical convolution, achieving high grounding contact consistency without requiring complex positioning fixtures or procedures during manufacturing.
Data Source
AI summary
An armored cable assembly with grounding path component equipped armor and a method of producing the same is provided. The armored cable includes an SZ cabled core having a binder tape wrapped conductor bundle that includes a first ground conductor. A second ground conductor is positioned outside the binder tape such that it is aligned with the longitudinal axis of the SZ cable core and contacts the interlock armor at each helical convolution. Also included is a low profile armored cable that includes a SZ cabled core.