Composite Cable Shield Conductor for Disconnection Resistance
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Solution Overview
Problem
Conventional composite cables for electric brakes are prone to signal line disconnection due to vertical vibration and horizontal shaking, especially when attached to a vehicle body and a wheel, leading to instability and poor durability.
Innovation Solution
A composite cable design featuring a signal line with a pair of twisted wires, power supply lines, and a conductive element wire shield conductor spirally wound around the signal line, enhancing shape retainability and rigidity, and allowing for improved flexibility and reduced tensile forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional composite cable is subjected to vertical vibration in a bending state, then the cable experiences horizontal shaking, but the signal line is easily disconnected due to tensile force applied during rapid bending
Solution Approach 1:
A shield conductor composed of a flexible resin tape with a metal foil layer is wrapped around the signal line part. This flexible shield structure follows the bending of the cable during vertical vibration without restricting the signal line's movement, preventing tensile force concentration that would cause disconnection, while still providing electromagnetic shielding.
Solution Approach 2:
The shield conductor uses a composite structure combining a resin base material with a metal foil layer. The resin provides flexibility to accommodate cable bending and vibration, while the metal foil layer provides electromagnetic shielding capability, achieving both disconnection resistance and signal protection.
2Stability of the object's composition
If a shield conductor is added to improve shape retainability and reduce horizontal shaking, then the cable rigidity increases, but the flexibility and followability to bending may be restricted
Solution Approach 1:
The shield conductor uses a flexible resin tape structure that can bend and deform with the cable during vertical vibration. This flexible shield does not restrict the cable's ability to follow bending movements, maintaining good flexibility and followability while still providing shape retainability and reducing excessive horizontal shaking.
Solution Approach 2:
The shield conductor is designed to dynamically respond to cable movement during vibration. The flexible resin tape allows the shield to adapt its shape during bending and vibration, maintaining close contact with the signal line without imposing rigid constraints, thus preserving cable flexibility while providing stabilization.
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 significantly enhances disconnection resistance and flexibility, preventing rapid bending and horizontal shaking, thus ensuring reliable signal transmission even under vibrational stress.
Implementation Method 1
the signal line part is covered with a shield conductor formed of a conductive element wire spirally wound around an outer circumference of the signal line part
Data Source
AI summary
A composite cable which makes it possible to improve disconnection resistance of a signal line. The 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 conductive element wire spirally wound around the outer circumference of the signal line part.