Composite Cable Friction Reduction via Spiral Tape and Twist Direction
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Solution Overview
Problem
The existing composite cables used in vehicles for connecting wheel-side and vehicle-body side components, such as electro-mechanical brakes and sensors, face issues with lubricant scattering during termination, leading to a deteriorated working environment and potential stress on electric wires due to friction.
Innovation Solution
A composite cable design featuring a first and second twisted-pair wire, with a larger third electric wire arranged circumferentially, and a tape member spirally wound around the assembled article, where the twisted-pair wires have the same twist direction but differ from the assembled article's twist direction, and the tape member's winding direction differs from the assembled article's twist direction, reducing friction without using lubricants like talc powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lubricant such as talc powder is interposed between electric wires and sheath to reduce friction and improve flex resistance, then the flex resistance is improved, but the lubricant may be scattered in the workplace during cable termination causing deterioration of the working environment
Solution Approach 1:
The harmful lubricant material is extracted and removed from the cable structure. Instead of using talc powder or similar lubricants between the electric wires and sheath, the invention employs a lubricant-free design where the electric wires are directly housed in the sheath without any interposed lubricating material, thereby eliminating the source of workplace contamination while maintaining cable flexibility through proper wire arrangement and sheath design
Solution Approach 2:
A tape member is introduced as an intermediary element between the electric wires and the sheath. This tape member serves as a mediator that reduces friction and improves flex resistance without using scattered lubricant materials. The tape provides a controlled interface that allows the electric wires to move smoothly within the sheath during bending and routing operations without releasing particles into the workplace environment
2Adaptability or versatility
If multiple electric wires are housed in one sheath to form composite cable for connecting wheel side and vehicle body side, then the cable integration is achieved, but friction between electric wires and sheath increases stress on electric wires during bending
Solution Approach 1:
The tape member acts as an intermediary between the electric wires and the sheath, reducing direct contact and friction. This intermediary layer allows the wires to slide more easily within the sheath during bending operations, reducing stress and preventing damage while maintaining the integrated composite cable structure that houses multiple wires for connecting wheel-side and vehicle-body side components
Data Source
AI summary
A composite cable includes a first twisted-pair wire formed by twisting a pair of first electric wires, a second twisted-pair wire formed by twisting a pair of second electric wires, a pair of third electric wires arranged between the first and second twisted-pair wires in a circumferential direction, each third electric wire having a larger outer diameter than the first and second electric wires, and a tape member spirally wound around an assembled article that is formed by twisting the first twisted-pair wire, the second twisted-pair wire and the pair of third electric wires together. The two twisted-pair wires have the same twist direction, the twist direction of the two twisted-pair wires is different from a twist direction of the assembled article, and the twist direction of the assembled article is different from a winding direction of the tape member.