Power Cable Harness Limiting Rings for Weld Point Protection
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Solution Overview
Problem
The limited wiring space and curved paths inside servers and energy storage cabinets lead to excessive stress on cable assemblies, causing damage to weld points.
Innovation Solution
A power cable design featuring a wire harness limiting member with first and second limiting rings surrounding the welding ends, supported by a bridge, to prevent excessive bending and protect weld points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the cable assembly uses a curved wiring path to adapt to limited wiring space, then the adaptability to wiring space constraints is improved, but the stress on weld points increases causing damage
Solution Approach 1:
The wire harness is segmented into multiple flexible branches, each capable of independent movement within limits. This segmentation allows the cable assembly to adapt to curved wiring paths while distributing stress across multiple segments rather than concentrating it at the weld points, thus maintaining reliability while improving adaptability.
Solution Approach 2:
The wire harness uses flexible cables with adjustable bending radii and movement ranges. By changing the physical parameters of the cable (flexibility, length, bending radius), the system can adapt to different wiring space configurations while maintaining sufficient mechanical strength to protect weld points from excessive stress.
2Ease of operation
If the wire harness is made flexible to allow movement in limited space, then the ease of installation and adaptability is improved, but the weld points become vulnerable to excessive stress and damage
Solution Approach 1:
The wire harness is designed with dynamic flexibility, allowing controlled movement and bending during installation and operation. The flexible cable structure enables easy routing and installation while the movement is constrained within safe limits to prevent excessive stress on weld points, thus maintaining both ease of operation and weld point strength.
Solution Approach 2:
The design incorporates pre-planned stress distribution mechanisms through the flexible cable structure and routing geometry. By anticipating potential stress concentrations, the wire harness geometry is designed to distribute loads before they reach the weld points, cushioning them against excessive stress while maintaining flexibility for easy installation.
Data Source
AI summary
This disclosure is directed to a power cable having a connector, a first wire harness, a second wire harness and a limiting member. The connector has an insulative base, a first conductor and a second conductor. The first conductor and the second conductor are buried in the insulative base. The first wire harness has a first welding end, and the first welding end is connected to the first conductor. The second wire harness has a second welding end, and the second welding end is connected to the second conductor. The limiting member has a first limiting ring and a second limiting ring. The first limiting ring surrounds the first welding end, and the second limiting ring surrounds the second welding end.