Composite Cable Shield Conductor for Vibration Resistance
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Solution Overview
Problem
Conventional composite cables used in electric brakes are prone to signal line disconnection due to horizontal shaking caused by vertical vibrations, especially when one end is fixed to a vehicle body and the other end is attached to a vibrating wheel area.
Innovation Solution
A composite cable design featuring a signal line and power supply lines twisted together, covered with a shield conductor made of braided conductive element wires, which enhances rigidity and torsion resistance, reducing the likelihood of disconnection during vertical vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional composite cable without shield conductor is used, then the cable structure is simple and easy to manufacture, but the cable is prone to horizontal shaking and signal line disconnection when subjected to vertical vibration
Solution Approach 1:
The shield conductor is nested within the cable structure, positioned between the signal line and the outer sheath. This nested configuration allows the shield conductor to be integrated into the existing cable architecture without requiring separate external components, thereby improving signal line disconnection resistance while maintaining manufacturing simplicity
Solution Approach 2:
The shield conductor acts as an intermediary element between the signal line and the external environment. It provides mechanical support and stabilization to the signal line, preventing horizontal shaking during vertical vibration, while also offering electromagnetic shielding functionality
2Ease of operation
If the cable is made more flexible to accommodate vibration, then the cable can better absorb vertical vibration, but the horizontal shaking of the cable increases
Solution Approach 1:
The shield conductor is positioned specifically around the signal line portion that is most susceptible to horizontal shaking during vertical vibration. This localized placement provides targeted stabilization where needed most, while allowing other parts of the cable to maintain their flexibility for vibration absorption
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 shield conductor improves the cable's resistance to horizontal shaking and torsion, effectively preventing signal line disconnections, thereby enhancing the reliability and durability of electric brake systems.
Implementation Method 1
the rigidity of the cable is improved by the shield conductor in comparison with the conventional composite cable that has no shield conductor provided
Implementation Method 2
because the shield conductor is restricted in movement of the conductive element wires when the cable is horizontally shaking so as to hardly produce gaps between the winding of the element wires, the composite cable is excellent in torsion resistance
Data Source
AI summary
A composite cable includes a signal line part, a pair of power supply lines, and a sheath. The signal line part is composed of a first signal line and a second signal line twisted together. Each of the first signal line and the second signal line is composed of a pair of wires twisted together. The sheath covers an outer circumference of a wire bundle composed of the signal line part and a pair of power supply lines, the signal line part and the pair of power supply lines being twisted together. The signal line part is covered with a shield conductor formed of a braid composed of a plurality of conductive element wires braided together.