Movable Cable Fiber-Like Aluminum Alloy Fatigue Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional movable cables, particularly those made of aluminum alloys, face challenges with low flexural fatigue resistance, leading to potential wire breaking under repeated deformation, and require additional materials like copper for enhanced strength, which increases weight and reduces flexibility.
Innovation Solution
A movable cable with a conductor made from a specific aluminum alloy material having a fiber-like metal structure with aligned crystal grains, optimized alloy composition, and insulation coating, providing enhanced strength, flexibility, and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum-based materials are used to reduce weight, then weight is reduced, but flexural fatigue resistance becomes insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the alloy composition (Mg: 0.03-1.8%, Si: 0.01-2.0%, Fe: 0.01-1.5%, and other elements within specified ranges) and the crystal grain size (average dimension perpendicular to longitudinal direction ≤400nm). This transforms pure aluminum into a high-performance aluminum alloy that achieves both weight reduction and enhanced flexural fatigue resistance through compositional and structural parameter optimization.
Solution Approach 2:
The patent creates a composite material system by combining multiple alloying elements (Mg, Si, Fe, and optional elements like Cu, Ag, Zn, Ni, Co, Au, Mn, Cr, V, Zr, Ti, Sn) within the aluminum matrix. This composite approach leverages the synergistic effects of different elements to simultaneously improve strength, corrosion resistance, and flexural fatigue resistance while maintaining the lightweight advantage of aluminum.
2Strength
If copper alloy materials are used to increase strength, then strength is improved, but cable weight increases and flexibility deteriorates
Solution Approach 1:
The patent uses parameter changes to achieve high strength without increasing weight by controlling the aluminum alloy composition and crystal grain structure. The specified alloy ranges and the ≤400nm crystal grain size requirement enable the aluminum alloy to attain strength levels comparable to or exceeding copper alloys while maintaining aluminum's density advantage and flexibility.
Solution Approach 2:
The patent replaces expensive copper-based materials with more economical aluminum-based materials. By implementing the specific alloy composition and crystal grain control, the aluminum alloy achieves sufficient durability and strength for cable applications, making it a cost-effective alternative that eliminates the need for heavier copper construction.
3Strength
If copper coating is applied to aluminum alloy wire to increase strength, then strength is improved, but flexural fatigue resistance deteriorates due to crack formation
Solution Approach 1:
The patent extracts and eliminates the copper coating layer that causes flexural fatigue problems. Instead of coating aluminum with copper, the invention uses a properly formulated aluminum alloy with controlled crystal grain size (≤400nm) that inherently achieves the required strength without the harmful copper layer that initiates cracks during repeated flexing.
Solution Approach 2:
The patent removes the copper coating approach entirely, replacing it with a pure aluminum alloy solution. This eliminates the interface between copper and aluminum that creates crack initiation sites, thereby improving flexural fatigue resistance while maintaining strength through alloy composition and microstructure control.
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 achieves equal or higher strength and excellent flexural fatigue resistance compared to conventional cables, while maintaining a lightweight design, suitable for applications like elevator and robot cables.
Implementation Method 1
a specific aluminum alloy material having an alloy composition as described above, a fiber-like metal structure in which crystal grains extend to be aligned in one direction, and an average value of a dimension perpendicular to a longitudinal direction of the crystal grains in a cross-section parallel to the one direction of 400 nm or less
Data Source
AI summary
The present invention provides a movable cable, which has strength that is at least equal to conventional movable cables while having excellent flexural fatigue resistance and flexibility as well as being lightweight. This movable cable 10 has an electric conductor therein. The conductor comprises a first conductor 2 made of a specific aluminum alloy material wherein: the alloy composition contains, in mass %, 0.05-1.8% Mg, 0.01-2.0% Si, 0.01-1.5% Fe, and at least a total of 0.00-2.00% of one element selected from the group consisting of Cu, Ag, Zn, Ni, Co, Au, Mn, Cr, V, Zr, Ti and Sn, the balance being Al and unavoidable impurities; the crystal grains have a fiber-like metal structure in which the crystal grains all extend in one direction; and in a cross-section parallel to the one direction, the average crystal grain dimension perpendicular to the longitudinal direction is 400 nm or less. The ratio X of the area of the first conductor 2 in the whole conductor of the movable cable 10 is in the range of 10-100%.