Conductive Path With Movable Protective Pipe
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Solution Overview
Problem
Single-core cables lack flexibility and are prone to breakage under external forces, making it challenging to route them in confined spaces while maintaining electrical integrity and avoiding interference with fixing devices.
Innovation Solution
A conductive path design where a single-core cable is surrounded by a pipe that can move between protective and exposed positions, allowing the single-core cable to be protected over a long region, with stranded cables fixed to exposed ends of the single-core cable using ultrasonic welding, and the pipe's inner diameter is sized to accommodate both the single-core and stranded cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a single-core cable is used to reduce outer diameter for routing in low-height spaces, then the cable can be routed in smaller spaces, but the cable becomes hard to bend and deform
Solution Approach 1:
The conductive path is segmented into multiple cable types: single-core cables for straight runs where small diameter is needed, and stranded cables for sections requiring bending and deformation. This segmentation allows each cable type to perform optimally in its designated zone.
Solution Approach 2:
The single-core cable is inserted into a protective pipe that also accommodates stranded cables. This nesting structure allows the rigid single-core cable to be protected while the flexible stranded cables provide adaptability at connection points.
2Volume of moving object
If a single-core cable is used to reduce outer diameter, then the cable can be routed in low-height spaces, but the cable is prone to breakage under external forces
Solution Approach 1:
A protective pipe is placed around the single-core cable before installation to cushion it against external forces. This pre-protection prevents breakage from mechanical stress, impacts, or compression that may occur during routing and operation.
Solution Approach 2:
The protective pipe acts as a flexible shell that surrounds and protects the rigid single-core cable. This shell absorbs external forces while allowing the cable to maintain its structural integrity.
3Reliability
If the pipe is positioned to protect the single-core cable, then the cable is protected from external forces, but the exposed end portions needed for welding cannot be surrounded
Solution Approach 1:
The protective pipe is designed to be movable along the cable assembly. During manufacturing, the pipe can be positioned to expose end portions for welding operations, then moved to cover and protect the cable in the final installation. This dynamic positioning resolves the conflict between protection and accessibility.
Solution Approach 2:
The welding operations are performed before the protective pipe is positioned over the cable ends. This preliminary action allows the ends to be exposed during manufacturing while ensuring protection is in place before the cable is installed in its final position.
Data Source
AI summary
A single-core cable is protected over a long region by a pipe. A conductive path includes: a single-core cable in which end portions of a single-core wire are exposed; a first stranded cable in which an end portion of a first stranded wire that is exposed is coaxially fixed to the one end portion of the single-core wire; a second stranded cable in which an end portion of a second stranded wire that is exposed is coaxially fixed to the other end portion of the single-core wire; and a pipe that has an inner diameter dimension capable of surrounding the single-core cable and the first stranded cable, and is axially displaceable between a protective position at which only the single-core cable is surrounded, and an exposed position at which the one end portion of the single-core wire and the first stranded cable are surrounded, and the other end portion of the single-core wire is exposed.