Multi-DOF Cable Clamp for Suspension-Induced Cable Strain
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Solution Overview
Problem
Existing cable and hose connections in electric vehicles and movable systems experience strain and wear due to suspension movement, leading to reduced lifespan and potential failure.
Innovation Solution
A multiple degree of freedom cable clamp system with pivotable or flexible components, such as Cardan-joints, ball-and-socket joints, and elastomeric flanges, allows cables and hoses to move with the suspension system, reducing strain and extending their life expectancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If cables are rigidly mounted to the vehicle structure, then cable positioning is stable, but suspension movement causes strain and wear on the cables
Solution Approach 1:
The cable clamp is designed with pivotable mounting mechanisms that allow it to dynamically adjust its position and orientation in response to suspension movement. The clamp body can pivot relative to both the vehicle structure and the cable, enabling the system to accommodate jounce and rebound motions without transmitting excessive strain to the cable, thereby maintaining both positioning stability and cable reliability
Solution Approach 2:
The cable clamp acts as an intermediary component between the rigid vehicle structure and the flexible cable. By introducing this intermediate pivotable mounting system, the clamp absorbs and accommodates suspension movements through controlled pivoting, preventing direct transmission of mechanical stress to the cable while maintaining secure cable positioning
2Reliability
If cables are allowed to move freely with suspension movement, then strain on cables is reduced, but cable positioning becomes unstable
Solution Approach 1:
The dual-pivot design enables controlled movement rather than free movement. The clamp body pivots in a first direction relative to the vehicle structure and in a second direction relative to the cable, creating a dynamic positioning system that adapts to suspension motion while maintaining stable cable engagement through the constrained pivot mechanisms
3Device complexity
If a single degree of freedom mounting is used, then the mounting structure is simple, but it cannot accommodate multi-directional suspension movement
Solution Approach 1:
The system transitions from a static single-degree-of-freedom mounting to a dynamic multi-degree-of-freedom mounting system. The clamp body's ability to pivot in multiple directions (first direction relative to vehicle structure, second direction relative to cable) provides the adaptability needed to accommodate complex suspension movements while maintaining reasonable structural simplicity through the use of sequential pivot joints
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 clamp system effectively accommodates suspension movement, reducing strain on cables and hoses, thereby increasing their durability and longevity.
Implementation Method 1
the clamp body includes a Cardan-joint for pivotally mounting to the vehicle structure
Implementation Method 2
the clamp body is mounted to the vehicle structure by a ball and socket joint
Implementation Method 3
the mounting flange is formed from an elastomeric material
Data Source
AI summary
A vehicle drive system includes a vehicle structure and a suspension system connected to the vehicle structure. An electric motor is mounted to the suspension system and includes a drive member. A wheel is drivingly connected to the drive member. At least two electric cables are connected to the electric motor. A cable clamp has a clamp body including a first portion and a second portion defining at least two apertures for receiving the at least two electric cables, the clamp body being pivotably mounted to the vehicle structure.