Composite Cable Layout for Thin, Bend-Resistant Robot Wiring
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Solution Overview
Problem
The challenge is to provide extremely thin composite cables with an outer diameter of 1.0 mm or less that are resistant to repeated bending, twisting, and shaking, as they are used in narrow spaces within downsized robots and other applications.
Innovation Solution
The composite cable design includes a cable core composed of multiple signal lines, power lines, and a drain wire, where the outermost layer of the signal line is a shield layer, and either the power line or drain wire is positioned in the valley-like spaces between the signal lines, with all components made of copper alloy wires with a tensile strength of 800 MPa or more, and a sheath covering the binder tape to maintain the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cable diameter is reduced to meet miniaturization requirements, then the space for wiring is reduced and robot size is decreased, but the cable becomes more prone to breaking under repeated bending operations
Solution Approach 1:
The cable core is segmented into multiple independent elements (signal lines with shield layers, power lines, drain wire) that are arranged in a specific pattern. Each element can move independently within the cable core, distributing the bending stress across multiple segments rather than concentrating it on a single structure, thereby improving breaking resistance while maintaining small diameter
Solution Approach 2:
The patent employs a nested structure where the power line and drain wire are positioned in valley-like spaces between the signal lines. This nested arrangement maximizes the utilization of internal space, allowing the cable to maintain a small outer diameter while accommodating multiple conductors with adequate spacing to prevent stress concentration and breaking
2Adaptability or versatility
If multiple cables are wired inside the robot to improve functionality, then the robot performance is enhanced, but the space required for wiring increases
Solution Approach 1:
Multiple functional cables (signal lines, power lines, drain wire) are merged into a single composite cable structure. This consolidation provides the versatility of multiple functions while occupying the space of only one cable, thereby enhancing robot functionality without increasing wiring space requirements
Solution Approach 2:
The composite cable serves multiple functions simultaneously - signal transmission, power supply, and drainage - within a single structural unit. This multi-functionality allows the robot to achieve enhanced performance without requiring separate cables for each function, thus avoiding increased wiring space
Data Source
AI summary
A composite cable having an outer diameter of 1.0 mm or less is provided with a cable core including multiple signal lines, a power line with an outer diameter smaller than an outer diameter of the signal line, and a drain wire with an outer diameter smaller than the outer diameter of the power line, and a sheath covering around the cable core. An outermost layer of the signal line is a shield layer, and either one of the power line or the drain wire is arranged in each valley-like space between the multiple signal lines arranged in contact with one another inside the cable core.