Composite Cable Spiral Layout for Thin Redundant Harnesses
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Solution Overview
Problem
Conventional composite cables for electric brake systems have a thick outer diameter due to redundant communication lines and power wires, which reduces routability and increases the risk of breakage from repeated bending.
Innovation Solution
A composite cable design featuring multiple power lines, first signal lines for control, and redundant second signal lines, where the signal lines are twisted together and spiral-shaped around a central axis within a sheath, reducing the overall cable diameter while maintaining redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two communication lines and an electric wire are covered together with a sheath as a single cable, then redundancy for reliability is achieved, but the outer diameter of the cable becomes thicker
Solution Approach 1:
The cable is segmented into distinct functional groups: power lines are bundled separately from signal lines, and communication lines are twisted into pairs. This segmentation allows each group to be optimized independently, reducing the overall cable diameter while maintaining all necessary functions including redundancy.
Solution Approach 2:
Signal lines are arranged in a twisted pair configuration, utilizing three-dimensional spatial arrangement rather than simple parallel bundling. This dimensional optimization reduces the cross-sectional area required for the same functional capacity, thereby reducing outer diameter.
2Volume of moving object
If the cable outer diameter is reduced, then routability is improved, but the cable may break easily due to repeated bending
Solution Approach 1:
The cable structure is segmented with each line individually insulated and then grouped. This segmentation allows each conductor to move independently during bending, reducing stress concentration and preventing breakage while maintaining a compact overall diameter.
Solution Approach 2:
The cable employs composite construction with multiple insulation layers, a protective sheath, and strategically arranged conductor groups. This composite structure provides both flexibility for bending and strength to prevent breakage, resolving the contradiction between reduced diameter and bending endurance.
3Reliability
If multiple signal lines are included for redundancy, then reliability is improved, but the cable complexity increases
Solution Approach 1:
Multiple signal lines are merged into twisted pairs, combining multiple conductors into a compact, organized structure. This merging reduces cable complexity by creating a systematic arrangement that is easier to manufacture, install, and maintain while preserving all redundant signal paths.
Solution Approach 2:
The twisted pair structure serves multiple functions simultaneously: it provides signal transmission, reduces electromagnetic interference, enables redundancy, and maintains a compact form factor. This multi-functionality reduces overall system complexity despite including multiple lines for redundancy.
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 a thinner cable with enhanced flexibility and reliability by allowing redundant signal lines to take over in case of damage, improving routability and bending endurance.
Implementation Method 1
the plurality of first signal lines and the plurality of second signal lines are collectively twisted in a spiral shape around a central axis of the signal line section
Data Source
AI summary
A composite cable includes a plurality of power lines for supplying operating power to a device to be controlled, a plurality of first signal lines for transmitting control signals for controlling the device to be controlled, a plurality of second signal lines for redundancy of the plurality of first signal lines; and a sheath collectively covering the plurality of power lines, the plurality of first signal lines, and the plurality of second signal lines, wherein a signal line section where the plurality of first signal lines and the plurality of second signal lines are twisted together and the plurality of power lines are stranded together inside the sheath, and wherein the plurality of first signal lines and the plurality of second signal lines are collectively twisted in a spiral shape around a central axis of the signal line section.