Gimbal Camera Cable Routing Through Rotation Axis
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Solution Overview
Problem
In small gimbal cameras, the limited space and high torque from wire routing lead to wire breakage, overheating, and reduced operational lifetime due to small bending radius and large rotation angles, causing signal interference and reduced controllability.
Innovation Solution
A camera assembly with a cable configuration that includes a transition segment bending around the gimbal's rotation axis, increasing the bending radius and angle, and using multiple wire stocks with a flexible printed circuit to reduce torque and pulling force, allowing the cable to pass through the rotation center.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gimbal volume is increased to provide sufficient moving space for the wire, then the wire can be properly configured with adequate bending radius, but the gimbal camera device becomes large in volume
Solution Approach 1:
The cable is segmented into multiple parts: a first cable segment connected to the camera module, a second cable segment connected to the motor, and a third cable segment connecting to the external device. The transition segment acts as a flexible connector between these segments, allowing each segment to be optimized for its specific function while maintaining overall cable flexibility and reducing stress on any single segment
Solution Approach 2:
The cable routing transitions from a planar two-dimensional layout to a three-dimensional spatial configuration. The cable passes through the rotation center and utilizes the Z-axis dimension (along the rotation axis) to create a transition segment that bends around the first rotation axis, effectively increasing the bending radius without increasing the lateral footprint of the gimbal
2Ease of operation
If a wire is configured in the small gimbal space, then connectivity is achieved, but the wire experiences large torque and pulling force during rotation, causing wire breakage and motor overheating
Solution Approach 1:
The cable is routed to pass through the rotation center of the gimbal, creating a pivot point that remains stationary during rotation. This equipotential routing ensures that the cable experiences minimal tension and torque variations throughout the rotation cycle, as the cable enters and exits the rotating assembly at the same radial position, eliminating the leverage arm that would otherwise create excessive torque
Solution Approach 2:
The transition segment acts as an intermediary element between the camera module and the external device. This transition segment absorbs the mechanical stress and torque generated during rotation, protecting both the camera module connections and the motor connections from excessive force that could cause wire breakage or motor overheating
3Volume of moving object
If the bending radius of the wire stock is small to fit the compact gimbal, then the gimbal remains compact, but the rotation angle becomes large causing large internal stress in the wire stock
Solution Approach 1:
The cable routing utilizes the third dimension (Z-axis along the rotation axis) to create a transition segment that bends around the first rotation axis. This spatial configuration effectively increases the bending radius by utilizing the depth dimension of the gimbal rather than constrained to the lateral plane, reducing internal stress in the wire stock while maintaining compact lateral dimensions
Solution Approach 2:
The transition segment is configured to bend in a curved path around the first rotation axis rather than sharp angular bends. This curved routing increases the effective bending radius and distributes the stress more evenly along the cable length, reducing peak internal stress in the wire stock during large-angle rotations
4Device complexity
If ordinary wire stock is used for cable routing, then the structure is simple, but signal interference occurs between components due to lack of shielding
Solution Approach 1:
The cable employs a composite structure combining multiple wire stocks with different functions: signal transmission wires, power wires, and a flexible printed circuit board. This composite cable assembly integrates both electrical connectivity and mechanical flexibility in a single integrated structure, reducing the need for separate shielding components while providing inherent signal protection through the multi-layer construction
Data Source
AI summary
A camera assembly of a gimbal structure is provided. The camera assembly includes a housing and a camera module disposed inside the housing. The camera assembly also includes a cable disposed inside the housing. The cable includes a first connection end, a second connection end, and a transition segment disposed between and connecting the first connection end and the second connection end. The first connection end is configured to connect with the camera module, the second connection end is configured to connect with an external device located outside of the housing. The transition segment includes a first transition segment disposed bending around a first rotation axis of the gimbal structure. The camera assembly is configured to rotate around the first rotation axis of the gimbal structure.