Keyed Electrical Cable Assembly for Tool-Free Component Connection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical cable installation technologies are inflexible and complex, particularly in industrial applications where precise cable length and simplified connection methods are required, especially for Industrial Internet of Things (IIOT) applications using Ethernet technology.
Innovation Solution
A cable with a coding or connection structure that allows for direct connection to a component without the need for crimping or stripping, featuring a plug structure and coding that ensures correct alignment and contact, enabling easy assembly and adaptation to desired lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pre-assembled cables are used during installation, then the installation process is simplified, but the flexibility and adaptability to different application requirements are reduced
Solution Approach 1:
The cable is divided into modular sections with standardized connectors at both ends, allowing the cable to be segmented and reconfigured to different lengths and configurations as needed in the field, thus maintaining flexibility while simplifying installation through pre-assembled modular units
Solution Approach 2:
The cable design incorporates universal connectors and standardized interfaces that can be used across different applications and configurations, enabling the same cable type to serve multiple functions and adapt to various installation requirements without requiring custom cable assemblies
2Adaptability or versatility
If field assembly of cables is performed, then the flexibility and adaptability are improved, but the complexity of the assembly process increases
Solution Approach 1:
The cable is pre-assembled with connectors, stripping, and crimping already completed during manufacturing, so that when field assembly is required, only simple connection steps remain, significantly reducing the complexity of field assembly while maintaining flexibility
Solution Approach 2:
The cable incorporates self-aligning and self-securing features such as keyed connectors and automatic locking mechanisms that guide the assembly process and ensure proper connection without requiring complex tools or procedures, thereby simplifying field assembly operations
3Reliability
If conventional connectors and cables are used for IIoT applications, then compatibility with existing systems is maintained, but the system complexity and cable length limitations increase
Solution Approach 1:
The cable design changes key parameters such as conductor arrangement, insulation thickness, and outer diameter to enable longer cable lengths and simplified routing while maintaining electrical performance and compatibility with standard connectors used in IIoT applications
4Manufacturing precision
If coding structures are added to the cable, then the alignment precision and connection reliability are improved, but the manufacturing complexity increases
Solution Approach 1:
The coding structure employs asymmetric geometric features such as keyed positions and shaped connectors that provide simple mechanical guidance for correct alignment during connection, achieving high alignment precision through straightforward asymmetric design rather than complex precision mechanisms
Data Source
Figure 1
Figure 2~3d
Figure 4~5
AI summary
The invention relates to an electrical cable (2) for connection with an electrical component (20), wherein the cable (2) has at least one electrical conductor (4).