Flat-Round Cable Structure for High-Motion Durability
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Solution Overview
Problem
Cables used in amusement park attractions frequently malfunction due to repeated use in high motion environments, leading to damage and high maintenance costs.
Innovation Solution
A lightweight and durable cable design featuring multiple internal cables surrounded by an outer jacket, with round and flat portions, and incorporating heat shrink fabric, dividers, and strain relief pieces to withstand bending, stretching, and twisting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cable designs are used in high motion environments, then the cable can be simple and easy to manufacture, but the cable suffers damage quickly and requires frequent replacement
Solution Approach 1:
The cable is divided into multiple internal cables (power cable, data cable, audio cable) enclosed within a common outer jacket. Each internal cable is independently structured with conductors, insulation, and shielding layers, allowing individual optimization of function and durability while maintaining overall cable integrity under motion stress
Solution Approach 2:
The cable employs a nested structure where internal cables are housed within the outer jacket, and each internal cable contains conductors nested within insulation layers, which are further nested within shielding layers. This multi-layer nesting provides progressive protection against mechanical damage and environmental factors
Solution Approach 3:
The cable utilizes composite construction combining different materials: copper conductors for electrical transmission, polymer insulation for electrical isolation, metallic shielding for EMI protection, and durable outer jacket material for mechanical protection. This composite approach optimizes both durability and functional performance
2Reliability
If the cable is designed to withstand repeated bending and motion, then the cable durability improves, but the cable weight increases
Solution Approach 1:
The cable implements different structural characteristics at different locations: round portions at end regions for connector integration and strain relief, and flat portions in intermediate sections for flexibility and reduced bending radius. This localized structural optimization enhances durability without uniformly increasing weight throughout the entire cable
Solution Approach 2:
The cable structure accommodates dynamic motion through its flexible multi-layer construction and strategic positioning of rigid (round portions) and flexible (flat portions) sections, allowing the cable to adapt to repeated bending and stretching without permanent deformation or excessive weight
3Reliability
If the cable uses robust protective layers and complex internal structure, then the cable durability increases, but the manufacturing cost and complexity increase
Solution Approach 1:
The cable is manufactured by independently preparing each internal cable with its conductors, insulation, and shielding, then assembling them within the outer jacket. This segmented manufacturing approach allows standardized production of internal cables that can be replicated and assembled, simplifying the overall manufacturing process despite the complex final structure
Solution Approach 2:
The nested structure enables sequential manufacturing steps where inner layers are formed first, then outer layers are added in a systematic progression. This modular layering approach simplifies the manufacturing process by breaking down the complex multi-layer construction into manageable sequential operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The cable withstands over 150,000 testing cycles, significantly more than existing cables, ensuring reliable signal transmission and reducing maintenance needs.
Implementation Method 1
The outer jacket includes heat shrink fabric
Data Source
AI summary
A cable includes multiple internal cables configured to transmit electrical signals, an outer jacket that houses the internal cables, and round portions formed proximate to opposite end regions of the cable, wherein the internal cables are arranged to circumferentially surround a center axis in the round portions. In addition, the cable includes a flat portion positioned between the round portions of the cable, wherein the internal cables are arranged in a row across the flat portion.