Multifunctional Cable Straight Core Spiral Winding
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Solution Overview
Problem
The complexity of cable harnesses in the automobile industry has increased due to rising electrical components, making manual production and assembly challenging, particularly with stranded line elements that develop a wavy shape, complicating insulation stripping and fitting into plugs.
Innovation Solution
A multifunctional cable design featuring a straight core with inner and outer functional elements, where only the outer elements are wound in a spiral around the core, preventing stranding and allowing for easier manufacturing and assembly, with a press fit to secure the outer elements and an outer insulating sheath to fill gaps between windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual line elements are stranded with one another to form cable harnesses, then the cable harness can accommodate multiple electrical components and signal lines, but the individual line elements acquire a permanent wavy shape that makes assembly and insulation stripping more difficult
Solution Approach 1:
The cable harness is segmented into a straight core component and separate outer functional elements. The core remains straight and untwisted, while outer elements can be individually routed and connected. This segmentation allows the core to maintain its straight shape for ease of manufacturing while still accommodating multiple electrical components through the modular addition of outer elements.
2Adaptability or versatility
If the number of electrical consumers and sensors is increased to meet modern vehicle requirements, then the functionality of the electrical system is improved, but the complexity of the cable harness increases making manufacture and installation more difficult
Solution Approach 1:
The cable harness structure employs a nested configuration where outer functional elements are wound around or attached to a central straight core. This nesting allows multiple functional elements to be organized in a compact, structured manner around a simple core, increasing the number of accommodated components without proportionally increasing overall complexity.
3Adaptability or versatility
If manual working steps are used on a cable board for producing cable harnesses, then flexibility in handling different configurations is maintained, but the production process becomes relatively complicated and time-consuming
Solution Approach 1:
The core is prepared in advance as a straight, pre-formed component before the outer functional elements are added. This preliminary preparation of the core structure allows for more efficient assembly processes, as the foundational element is already in its final configuration, reducing the time and complexity of the overall production process while maintaining flexibility in adding different outer elements.
Data Source
AI summary
A multifunctional cable is particularly suitable for the automotive industry. The multifunctional cable has a plurality of functional elements. A core in the form of a sheathed line contains at least one inner functional element. At least one outer functional element is wound around the sheathed line core.