Composite Cable Twist Direction Design for Termination Workability
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Solution Overview
Problem
The existing composite cables require time and effort to terminate due to the need to remove lubricants like talc powder, which complicates the cable termination process.
Innovation Solution
A composite cable design featuring a pair of first electric wires, a twisted pair wire with a smaller outer diameter, and a tape member spirally wound around the assembled article, where the twist directions of the twisted pair wire and assembled article differ from the winding direction of the tape member, reducing friction and improving workability without the need for lubricants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lubricant such as talc powder is interposed between electric wires and a sheath to reduce friction and improve flex resistance, then flex resistance is improved, but cable termination workability deteriorates due to the need to remove the lubricant
Solution Approach 1:
The invention extracts and removes the lubricant (talc powder) from the cable structure, eliminating the need to remove it during termination while preserving the flex resistance benefits through the twisted pair configuration and tape member design
Solution Approach 2:
The tape member serves as an intermediary element that provides the necessary friction reduction and flex resistance without requiring removable lubricants, allowing smooth cable termination while maintaining operational reliability
2Stability of the object's composition
If the twist direction of the twisted pair wire is different from the twist direction of the assembled article, then stability against kinking is improved, but manufacturing complexity increases
Solution Approach 1:
The invention applies asymmetry by using different twist directions for the twisted pair wire versus the assembled article, creating a structure that inherently resists kinking while maintaining manufacturability through systematic implementation
3Reliability
If a tape member is spirally wound around the assembled article with a different winding direction from the twist directions, then flex resistance is improved and kinking is reduced, but the structure becomes more complex
Solution Approach 1:
The spirally wound tape member introduces a curved, spiral geometry that enhances flex resistance and prevents kinking by distributing mechanical stress evenly, while the systematic winding pattern maintains manufacturing feasibility
Data Source
AI summary
[Problem] Provided are a composite cable and a composite harness that allow the improvement of cable termination workability while maintaining the flex resistance.[Solution] A composite cable 1 is provided with a pair of first electric wires 2, a twisted pair wire 4 formed by twisting a pair of second electric wires 3 having a smaller outer diameter than the first electric wires 2 and a tape member 6 spirally wound around an assembled article 5 that is formed by twisting the pair of first electric wires 2 and the twisted pair wire 4 together, wherein a twist direction of the twisted pair wire 4 is different from a twist direction of the assembled article 5, and the twist direction of the assembled article 5 is different from a winding direction of the tape member 6.