Flex-Resistant Shielded Composite Cable for In-Wheel Motors
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Solution Overview
Problem
Traditional flex-resistant composite cables lack adequate shielding performance, which is necessary for applications involving in-wheel motor structures, leading to potential noise interference and increased risk of disconnection when flexed with wheel movement.
Innovation Solution
A flex-resistant shielded composite cable with a twisted conductor made of strands between 0.05 mm and 0.12 mm in diameter, a braided shielding layer of plated fibers, and a tubular sheath of insulating resin, along with a second electric wire arranged spirally between the shielding layer and the sheath to absorb line length differences during flexing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a composite cable is designed with high flex resistance using traditional structures, then flexing durability is improved, but shielding performance is insufficient leading to noise interference
Solution Approach 1:
The patent applies composite materials by combining multiple layers with different functions: a flexible inner sheath for flex resistance, a metallic shielding layer for EMI protection, and an outer protective sheath. This multi-layer composite structure simultaneously achieves both flexing durability and shielding performance that single-material structures cannot provide
Solution Approach 2:
The patent implements nesting by placing the shielding layer inside the outer sheath while containing the inner sheath and conductors within the shielding layer. This nested arrangement allows each layer to perform its specific function independently while contributing to the overall cable performance, achieving both flexibility and EMI shielding
2Ease of operation
If the conductor strands are made thinner to improve flexibility, then flex resistance is improved, but the risk of disconnection increases
Solution Approach 1:
The patent optimizes the strand diameter parameter to 0.05-0.12mm, which is thinner than traditional strands for improved flexibility but thick enough to maintain structural integrity. This precise parameter control allows the conductor to bend repeatedly without fatigue failure while still achieving the required flexibility for wheel movement applications
Solution Approach 2:
The patent divides the conductor into multiple fine strands (0.05-0.12mm diameter) rather than using a single thick wire. This segmentation allows individual strands to flex independently, distributing mechanical stress and reducing the risk of complete disconnection while maintaining overall conductor flexibility and electrical performance
3Object-affected harmful factors
If a shielding layer is added to provide EMI protection, then shielding performance is improved, but the cable structure becomes more complex
Solution Approach 1:
The patent uses a thin metallic shielding layer in the form of a braided or foil structure that provides effective EMI protection while adding minimal thickness and complexity. This thin-film approach achieves shielding performance without significantly increasing cable diameter or manufacturing complexity compared to traditional multi-component structures
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 solution provides enhanced flex resistance, prevents disconnection of electric wires, and suppresses noise interference, ensuring reliable operation of in-wheel motor systems by maintaining shielding performance and flexibility.
Implementation Method 1
a braiding formed by braiding plated fiber which are formed by performing metal-plating on anti-tension fiber
Data Source
AI summary
A flex-resistant shielded composite cable includes a plurality of electric wires, a shielding layer and a tubular sheath. Each of the electric wires includes a conductor part which is composed of a twisted wire, which is formed by twisting a plurality of strands having a diameter of 0.05 mm or more and 0.12 mm or less, a nominal sectional area of the conductor being 8 sq or more, a covering part covering the conductor part. The shielding layer is formed of a braid formed by braiding plated fiber formed by performing metal-plating on anti-tension fiber and covers outer periphery of the plurality of electric wires. The tubular sheath is provided on the outer periphery of the shielding layer and made of an insulating resin.