Non-Circular Cable Assembly Friction Reduction
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Solution Overview
Problem
Current cable assemblies for connecting throttle and engine assemblies in vehicles suffer from high frictional coefficients due to the materials and design, leading to poor engine control and excessive wear, necessitating frequent replacements and time-consuming recalibration.
Innovation Solution
A cable assembly design featuring a first cable with an inner channel and a second cable of a non-circular cross-sectional shape slidably disposed within, utilizing different materials and shapes to reduce friction, such as a hexagonal or decagonal shape for the second cable, and incorporating lubrication material to facilitate smoother operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional circular cable design is used, then manufacturing is simple, but frictional coefficient is high leading to poor engine control
Solution Approach 1:
The patent applies asymmetry by changing the cable cross-sectional shape from circular to non-circular (hexagonal, octagonal, or rectangular). This asymmetric geometry reduces the contact area between the inner and outer cables, thereby reducing frictional coefficient and enabling finer engine control while maintaining manufacturing feasibility through standard extrusion processes.
2Reliability
If traditional cable materials are used, then manufacturing is easy, but wear is excessive leading to frequent failure
Solution Approach 1:
The patent employs composite materials by combining different material properties in the cable construction. The inner cable uses a low-friction material such as PTFE (Teflon) or nylon, while the outer cable uses a durable, wear-resistant material. This composite approach reduces wear and extends cable assembly lifespan while remaining compatible with standard manufacturing processes.
3Ease of operation
If high friction is present, then cable structure is simple, but fine engine control is unavailable
Solution Approach 1:
The patent changes the geometric parameter of the cable cross-section from circular to non-circular (with 3-8 sides). This parameter change reduces the contact perimeter between sliding surfaces, directly reducing frictional force and enabling precise throttle control for fine engine management.
4Reliability
If cable assembly wears out, then replacement is necessary, but recalibration is time-consuming
Solution Approach 1:
The patent segments the cable assembly into modular components (inner cable, outer cable, connectors) that can be independently replaced. The non-circular cross-sectional design maintains consistent geometric relationships across segments, allowing for modular replacement without requiring full disassembly and recalibration of the entire system, thereby reducing maintenance time.
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
This design reduces frictional resistance, enabling finer control of the engine and extending the lifespan of the cable assembly by minimizing wear and simplifying recalibration processes.
Implementation Method 1
the second cable includes a generally non-circular cross-sectional shape... utilizing different materials and shapes to reduce friction
Implementation Method 2
incorporating lubrication material to facilitate smoother operation
Data Source
AI summary
The invention relates to a cable assembly. Specifically, the cable assembly includes a segment having a first cable and a second cable. The first cable defines an inner channel. The second has a non-circular cross-sectional shape and is slidably disposed in the inner channel. The non-circular cross-sectional shape of the second cable may improve the frictional coefficient between the first cable and the second cable.