Cable Bushing Shielding Plate for Control Housing
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Solution Overview
Problem
Existing cable bushings in automotive and electric vehicle applications face challenges with complex assembly processes, cable shielding, and inadequate electromagnetic compatibility (EMC) protection, particularly in high-voltage environments, where cables are prone to damage and leakage currents due to insufficient shielding and clearance distances.
Innovation Solution
A cable bushing design featuring a shielding plate that connects to the control housing's shielding, allowing unshielded cables to pass through while maintaining shielding, and incorporating a sealing mechanism to prevent moisture and dirt ingress, with a simplified assembly process that reduces cable damage and enhances EMC protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cables are stripped and provided with connection terminals inside the control housing, then electrical connection to the printed circuit board is achieved, but assembly work is increased and cables are prone to crushing and breaks
Solution Approach 1:
The cable connections are pre-assembled with connection terminals outside the control housing, then the entire cable assembly is plugged into the control housing as a complete unit. This preliminary assembly eliminates the need for stripping and terminal attachment inside the housing, reducing assembly complexity and preventing cable damage during installation.
Solution Approach 2:
The cable assembly is divided into separate modular components (cable, connection terminals, and control housing interface) that can be assembled independently outside the housing and then integrated as a complete unit. This segmentation allows for easier handling and reduces the risk of cable crushing during the assembly process.
2Reliability
If individual cables are shielded, then electromagnetic compatibility is improved, but the complexity and cost of cable preparation is increased
Solution Approach 1:
Multiple individual cable shields are merged into a single common shielding structure within the control housing. Instead of requiring each cable to have its own shield, the invention provides a unified shielding solution that protects all cables collectively, reducing complexity while maintaining EMC protection.
Solution Approach 2:
The shielding structure serves multiple functions simultaneously: it provides electromagnetic compatibility protection for all cables, acts as a grounding path, and serves as a structural element for mounting cables within the housing. This multi-functionality reduces the need for separate shielding components for each cable.
3Reliability
If clearances and creepage distances are increased to prevent leakage currents, then safety is improved, but the space required for cable routing is increased
Solution Approach 1:
Instead of uniformly increasing clearances throughout the entire cable routing path, the invention applies enhanced insulation and spacing only in critical areas where leakage currents could occur, such as near high-voltage connections and grounding points. This localized approach maintains safety while minimizing the overall space required for cable routing.
Solution Approach 2:
Insulating barriers and creepage-resistant materials are introduced as intermediary elements between conductive parts to prevent leakage currents. These intermediaries allow cables to be routed in closer proximity to each other and to housing surfaces while still maintaining the required electrical clearance and creepage distances for safety.
Data Source
Figure 1~4
Figure 3~5
Figure 6a~6e
AI summary
The present invention relates to a cable entry into a control housing (180) surrounding a printed circuit board (186), the control housing being provided with a feedthrough housing (102) having a contact surface (112) and fastening means (124) for attaching the feedthrough housing (102) to the control housing (180) and having receptacles (144, 145) for at least two cables (46) to be electrically connected to the printed circuit board (186). To simplify the assembly of the cable routing, the present invention proposes a shielding plate (108) forming a shielding surface (118) for contacting a shield (66) on the control housing side, wherein the shielding surface (118) is electrically conductively connected to a contact surface (126.1) that is exposed on a rear side of the feedthrough housing (102) facing away from the contact surface (112) for connection to a shield (172).