Braided Shield Cable Flex Resistance Design

Solution Overview

Problem

Cables with multi-layered braided shields for industrial robots suffer from reduced flexibility and twist resistance, leading to shorter lifespans due to fatigue, compromising their ability to withstand repeated bending and twisting.

Innovation Solution

A cable design featuring an inner braided shield layer of cross-braided metal wires and an outer braided shield layer of copper tinsel and metal wires, providing enhanced flex and twist resistance while maintaining electromagnetic interference shielding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If the braided shield layer is multi-layered to enhance shield property, then the electromagnetic interference shielding is improved, but the cable becomes inflexible and the outer braided shield layer may be broken by fatigue

Engineering Contradiction:

Improveelectromagnetic interference shieldingVSAvoidcable flexibility

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The braided shield layer is divided into two separate layers: an inner braided shield layer and an outer braided shield layer. Each layer can be independently designed with different materials and structures to optimize their respective functions. The inner layer focuses on electromagnetic shielding while the outer layer prioritizes flexibility and mechanical protection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the cable structure are assigned different properties. The inner braided shield layer uses metal wires optimized for electromagnetic shielding performance, while the outer braided shield layer uses copper tinsel wires optimized for flexibility and fatigue resistance. This allows each part to have the quality best suited for its specific function.

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If the braided shield layer is multi-layered to increase shield property, then the electromagnetic interference shielding is improved, but the lifetime of entire braided shield layer becomes shorter due to reduced twist resistance

Engineering Contradiction:

Improveelectromagnetic interference shieldingVSAvoidbraided shield layer lifetime

Core Design Contradiction:

Object-affected harmful factorsVSDuration of action of stationary object

Solution Approach 1:

The braided shield layer is divided into two separate layers: an inner braided shield layer and an outer braided shield layer. Each layer can be independently designed with different materials and structures to optimize their respective functions. The inner layer focuses on electromagnetic shielding while the outer layer prioritizes flexibility and mechanical protection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the cable structure are assigned different properties. The inner braided shield layer uses metal wires optimized for electromagnetic shielding performance, while the outer braided shield layer uses copper tinsel wires optimized for flexibility and fatigue resistance. This allows each part to have the quality best suited for its specific function.

Inventive Principle:

Principle #3Local quality

3Object-affected harmful factors

If the braided shield layer is multi-layered to enhance shield property, then the electromagnetic interference shielding is improved, but the cable becomes inflexible compared to single-layered design

Engineering Contradiction:

Improveelectromagnetic interference shieldingVSAvoidcable flexibility

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The braided shield layer is divided into two separate layers: an inner braided shield layer and an outer braided shield layer. Each layer can be independently designed with different materials and structures to optimize their respective functions. The inner layer focuses on electromagnetic shielding while the outer layer prioritizes flexibility and mechanical protection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the cable structure are assigned different properties. The inner braided shield layer uses metal wires optimized for electromagnetic shielding performance, while the outer braided shield layer uses copper tinsel wires optimized for flexibility and fatigue resistance. This allows each part to have the quality best suited for its specific function.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10340058B2Cable with braided shield

Publication Date: 2019.07.02 PROTERIAL LTD

AI summary

A cable with braided shield includes a conductor, an insulation layer arranged to cover a periphery of the conductor, a braided shield layer arranged to cover a periphery of the insulation layer, and a sheath arranged to cover a periphery of the braided shield layer. The braided shield layer includes an inner braided shield layer, and an outer braided shield layer provided on a periphery of the inner braided shield layer. The inner braided shield layer includes a braided shield braided to cross metal wires. The outer braided shield layer includes a braided shield braided to cross a copper tinsel wire and a metal wire.