Composite Braided Shield Cable for Lighter Flexible Routing
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Solution Overview
Problem
Industrial robot cables with braided copper or copper alloy shields are excessively heavy and rigid, making them difficult to handle and bend, leading to potential wire breakage and compromised shielding functionality.
Innovation Solution
A cable design featuring a braided shield layer composed of cross-braided aluminum or aluminum alloy and copper or copper alloy wires, which reduces weight and enhances flexibility while maintaining shielding effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a braided shield formed by braiding metal wires made of copper or copper alloy is used, then shielding effectiveness is improved, but weight increases excessively
Solution Approach 1:
The patent uses a composite braided shield structure combining copper wires (for electrical conductivity and shielding) and aluminum alloy wires (for weight reduction and mechanical strength). This composite approach allows the cable to maintain effective electromagnetic shielding while significantly reducing overall weight compared to pure copper braided shields.
2Object-affected harmful factors
If a braided shield formed by braiding metal wires made of copper or copper alloy is used, then shielding effectiveness is improved, but handling ease deteriorates due to high rigidity
Solution Approach 1:
The patent changes the material composition parameters of the braided shield by incorporating aluminum alloy wires with different mechanical properties compared to pure copper. The aluminum alloy components reduce the overall rigidity and restoring force of the shield layer, enabling the cable to be bent in smaller radii and handled more easily while maintaining shielding effectiveness through the copper component.
3Weight of moving object
If metal wires made of aluminum or aluminum alloy are used in the braided shield, then weight is reduced, but reliability deteriorates due to wire breakage
Solution Approach 1:
The patent creates a composite braided shield where copper wires provide electrical conductivity and shielding effectiveness, while aluminum alloy wires contribute weight reduction and enhanced mechanical strength. The synergistic combination ensures that aluminum wires do not break easily during bending operations, maintaining reliability while achieving weight reduction goals.
4Object-affected harmful factors
If a braided shield with high rigidity is used, then shielding effectiveness is maintained, but adaptability deteriorates due to difficulty in bending
Solution Approach 1:
The patent modifies the physical parameters of the braided shield by incorporating aluminum alloy wires that reduce the restoring force and rigidity of the shield layer. This parameter change enables the cable to adapt to various routing configurations and bending requirements in wiring operations while the copper component maintains effective electromagnetic shielding.
Data Source
AI summary
A cable includes a cable core including one or more electric wires, a shield layer covering around the cable core, and a sheath covering around the shield layer. The shield layer is composed of a braided shield including a plurality of first metal wires composed of aluminum or aluminum alloy and a plurality of second metal wires composed of copper or copper alloy. The plurality of first metal wires and the plurality of second metal wires are cross-braided.