Cable Assembly Swaged Portion Positioning Precision Tensile Strength
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Solution Overview
Problem
Conventional cable assemblies with swaged portions have issues with positioning precision and tensile strength due to incorrect fixation and limited mechanical support, leading to potential damage and reduced reliability.
Innovation Solution
A cable assembly design featuring a metal clamp and tuboid-shaped metal case with a swaged portion that securely fixes the outer conductor and insulator, enhancing positioning precision and tensile strength through elastic and plastic deformation, while also incorporating unswaged portions for reduced load on the outer insulator and improved sealing for water and dust resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the swaged portion is only fixed to the outer insulator of the coaxial cable, then the structure is simple, but the tensile strength of the cable is low
Solution Approach 1:
The patent combines the fixation function with the clamp by integrating the clamp into the swaged portion structure. The clamp, made of elastic material, is embedded within the swaged portion and works together with the outer insulator and outer conductor to provide enhanced tensile strength while maintaining structural simplicity.
Solution Approach 2:
The swaged portion utilizes composite material construction by combining the elastic clamp material with the metal case material. This composite structure allows the clamp to deform elastically under tension while the metal case provides rigid support, achieving high tensile strength without complicating the overall structure.
2Reliability
If the swaged portion is swaged from outside to be brought into pressure contact with the outer insulator, then the fixation is achieved, but the positioning precision deteriorates when fixed at wrong position
Solution Approach 1:
The patent replaces the purely mechanical pressure contact system with a system that incorporates elastic deformation. The elastic clamp material allows for self-adjustment and tolerance compensation during the swaging process, reducing the impact of positioning errors while maintaining reliable fixation.
Solution Approach 2:
The patent changes the physical state of the clamp material from rigid to elastic during the swaging process. The elastic material can deform to accommodate slight positioning variations and then maintains consistent contact pressure, ensuring reliable fixation even when manufacturing precision varies within acceptable ranges.
3Strength
If the clamp is made of metal sheet wrapped around the outer conductor, then the tensile strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent merges the clamp manufacturing with the metal case formation process. The clamp is formed as an integral part of the metal case through the swaging process, eliminating separate manufacturing and assembly steps. This integration improves tensile strength while maintaining manufacturing simplicity.
Solution Approach 2:
The clamp is pre-formed with the metal case structure during the swaging process rather than being added as a separate component. This preliminary action of forming the clamp within the swaging operation simplifies manufacturing by combining multiple functions into a single process step.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design achieves improved positioning precision and tensile strength of the cable assembly, reduces load on the outer insulator during bending, and enhances resistance to water and dust ingress, thereby increasing the reliability and durability of the cable assembly.
Implementation Method 1
the first end portion of the outer insulator is elastically deformed
Implementation Method 2
the first end portion of the clamp is plastically deformed
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
The invention provides a cable assembly with improved positioning precision of a swaged portion fixed to a cable and with improved tensile strength of the cable. An assembly A1 includes a cable 100, a clamp 200, and a metal case 300. The clamp 200 securely holds a protruding portion 121 of an outer conductor 120, which protrudes from a first end portion 111 on a Y-direction side of an outer insulator 110 of the cable 100. The metal case 300 includes a tuboid swaged portion 310 housing at least the first end portion 111 of the outer insulator 110 and a first end portion 210 of the clamp 200 on the Y'-direction side. The swaged portion 310 is swaged from outside to be brought into pressure contact with and fixed to at least the first end portion 111 and the first end portion 210 so that at least the first end portion 111 is elastically deformed and the first end portion 210 is plastically deformed.