Composite Cable Twisted-Wire Layout for Distortion-Free Assembly
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Solution Overview
Problem
Existing composite cables face challenges in laying grounding wires and linear fillers together in a well-balanced manner due to differences in stiffness, leading to potential distortion and permanent bending of the cable.
Innovation Solution
A composite cable design where all electric wires, including grounding wires, are composed of a conductor and an insulator, ensuring they are equal in composition and diameter, allowing for balanced laying and preventing distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If grounding wire and linear filler are laid together to form second twisted wire, then cable structure is completed, but laying becomes unbalanced and distortion occurs due to stiffness difference
Solution Approach 1:
The patent applies homogeneity by making the linear filler have substantially the same outer diameter as the coated electric wire. This creates uniformity in the second twisted wire components, allowing them to be laid together in a balanced manner without distortion, directly resolving the stiffness and dimensional mismatch problem.
Solution Approach 2:
The patent changes the physical parameters of the linear filler by specifying its outer diameter to match that of the coated electric wire. This parameter adjustment ensures that both components have comparable stiffness and dimensional characteristics, enabling balanced laying and preventing cable distortion.
2Ease of manufacture
If second twisted wire is formed with distorted outer shape, then cable assembly is completed, but permanent bending occurs in the composite cable
Solution Approach 1:
By ensuring the linear filler and coated electric wire have substantially the same outer diameter, the patent creates a homogeneous second twisted wire with uniform outer shape. This prevents the distortion that would otherwise lead to permanent bending, thereby improving cable reliability while maintaining ease of assembly.
3Device complexity
If grounding wire and linear filler have different stiffness, then cable production is simplified, but laying balance deteriorates
Solution Approach 1:
The patent adjusts the outer diameter parameter of the linear filler to match that of the coated electric wire. This parameter change balances the stiffness characteristics of both components, enabling them to be laid together harmoniously without compromising production simplicity.
Data Source
AI summary
A composite cable is composed of plural electric power wires, a first twisted wire made by laying plural signal wires together, a second twisted wire disposed opposite the first twisted wire with the electric power wires between the first twisted wire and the second twisted wire, and a sheath formed over plural electric power wires, the first twisted wire, and the second twisted wire. The second twisted wire is made by laying plural electric wires including a grounding wire together. Each of the plural electric wires of the second twisted wire is composed of a conductor and an insulator formed over the conductor.