Cross-Braided Multi-Cable Assembly for One-Step Shield Soldering
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Solution Overview
Problem
The assembly and soldering of cables with shielding layers are complex due to the need for individual soldering of each cable's shielding layer to corresponding components, making it difficult to efficiently assemble and solder multiple cables simultaneously.
Innovation Solution
A cable design featuring cross-braided fixing wires outside the cable sets to maintain them in a row, facilitating the cutting and peeling of the outer layer for simultaneous soldering, allowing for easier assembly and soldering of multiple cables at once.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple cables with shielding layers are individually soldered to components, then each cable's shielding layer is properly connected, but the assembly and soldering process becomes complicated and time-consuming
Solution Approach 1:
Multiple cable sets are bundled together with a common outer layer, and their shielding layers are merged into a single collective shielding structure. The fixing wires cross-braid all cable sets together, creating a unified assembly that can be soldered as one unit rather than individually, thus simplifying the assembly process while maintaining shielding effectiveness
Solution Approach 2:
The common outer layer serves multiple functions: it provides mechanical protection for all cable sets, maintains their bundled configuration, and facilitates collective handling during assembly and soldering operations. This multi-functional design eliminates the need for separate handling of each cable's outer layer
2Manufacturing precision
If multiple cables are individually handled during assembly, then each cable can be precisely positioned, but the overall assembly process becomes complicated
Solution Approach 1:
The fixing wires cross-braid multiple cable sets together, merging them into a single manageable unit. This allows the entire bundle to be positioned and soldered simultaneously as one assembly, greatly improving productivity while the inner structures of individual cable sets remain intact for precise electrical connections
3Reliability
If shielding layers of multiple cables are soldered separately, then each connection is secure, but the soldering process cannot be done at one time
Solution Approach 1:
The shielding layers of multiple cable sets are merged into a collective shielding structure within the common outer layer, allowing all soldering connections to be made simultaneously to a single ground point or bus bar. This unified soldering approach maintains reliable electrical connections for all cables while reducing total soldering time compared to individual soldering operations
Data Source
AI summary
A cable includes: plural cable sets each including a pair of core wires, a shielding layer covering the pair of core wires, and an outer layer covering the shielding layer; and plural fixing wires cross-braided outside the cable sets to keep the cable sets in a row position along a lateral direction.