Braided Shield Cable Flex Resistance
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Solution Overview
Problem
Cables with braided shields used in industrial robots for welding and assembly tasks suffer from bending and twisting fatigue, leading to wear and potential breakage due to insufficient flex and twist resistance, despite their electromagnetic interference shielding properties.
Innovation Solution
A cable design featuring a braided shield layer composed of copper tinsel wires and metal wires, where the copper tinsel wire has a larger outer diameter than the metal wire, providing enhanced flex and twist resistance while maintaining effective shielding properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a braided shield layer is used for EMI control, then shield property is improved, but the cable becomes susceptible to bending and twisting fatigue
Solution Approach 1:
The braided shield layer combines copper tinsel wires with high flexibility and metal wires with high strength to create a composite structure that simultaneously provides EMI shielding and resistance to bending and twisting fatigue
Solution Approach 2:
Different wire materials are assigned different functions: copper tinsel wires provide flexibility and basic shielding, while metal wires provide strength and fatigue resistance, creating localized functional differentiation within the braided shield layer
2Reliability
If copper tinsel wire and metal wire are used in braided shield, then both flex resistance and shield property can be achieved, but wire diameter selection affects overall performance
Solution Approach 1:
The patent specifies that the outer diameter of copper tinsel wire should be larger than that of metal wire, optimizing the balance between flexibility and strength while simplifying the overall braided shield structure design
Data Source
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 a braided shield braided to cross a copper tinsel wire and a metal wire. An outer diameter D1 of the copper tinsel wire is larger than an outer diameter D2 of the metal wire.