Composite Cable Sheath Structure for Shield Protection in Bending
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Solution Overview
Problem
The existing composite cables for electro mechanical brake devices suffer from local stress concentration and damage to the shield when bent, leading to a deterioration in electromagnetic noise shielding effectiveness.
Innovation Solution
The composite cable design includes a specific arrangement of internal cables, a first sheath, a shield, and a second sheath, where the shield is supported by the first sheath, and the second sheath is designed to reduce direct contact and stress concentration, using materials with varying flexibility and surface roughness to enhance movement and reduce deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the shield is directly covered by the outer sheath without internal support, then the cable structure is simpler, but the shield deforms when bent causing local stress concentration and damage
Solution Approach 1:
A first sheath is introduced as an intermediary component between the electric wire and the shield. This first sheath supports the shield from the inside, preventing direct contact between the shield and the outer sheath, thereby eliminating the need for complex external support structures while maintaining shield integrity during bending operations
Solution Approach 2:
The cable adopts a nested layered structure where the first sheath is positioned inside the shield, and the shield is positioned inside the outer sheath. This nested arrangement allows the inner first sheath to provide support to the shield without adding external complexity, resolving the contradiction between structural simplicity and shield reliability
2Shape
If the shield is deformed by centripetal force from the outer sheath, then the cable maintains compact shape, but the shield cross-sectional shape deforms causing stress concentration
Solution Approach 1:
The first sheath acts as a counterbalancing element that applies an outward supportive force on the shield from the inside, counteracting the inward centripetal force exerted by the outer sheath. This balanced force system prevents shield deformation and stress concentration while maintaining the cable's compact overall shape
3Shape
If the shield and other cables are in direct contact, then the cable structure is more compact, but the shield slides against cables causing damage to both
Solution Approach 1:
The first sheath serves as a protective intermediary layer between the shield and adjacent cables. This intermediate layer prevents direct sliding contact between the shield and cables, eliminating wear and damage to both components while maintaining cable compactness through the layered nested structure
Data Source
AI summary
A composite cable includes a plurality of internal cables and a covering member covering peripheries of the plurality of internal cables. At least one of the plurality of internal cables includes at least one electric wire having a conductor, a first sheath covering a periphery of the at least one electric wire, a shield covering a periphery of the first sheath, and a second sheath covering a periphery of the shield.