Radial Actuator Cable Routing Support for Automated IDC Assembly

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Solution Overview

Problem

Existing methods for assembling radial actuators in magnetic bearing modules are laborious, unreliable, and costly, lacking modularity and automation, with complex chemical processes and tools required for PCB-based connections.

Innovation Solution

A cable routing support with insulation displacement contacts and modular design, featuring protuberances, serigraphs, and notches for precise cable routing, allowing automated assembly and reducing chemical processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual splicing method is used for cable connections, then electrical isolation and mechanical positioning can be achieved, but the process becomes laborious, unreliable, and cannot be automated

Engineering Contradiction:

Improveconnection reliabilityVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical splicing operations with an automated insulation displacement contact system. The routing support with integrated IDC contacts and cable routing tracks enables automated insertion and connection, eliminating manual soldering and mechanical positioning steps while maintaining reliable electrical connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The routing support acts as an intermediary component that integrates cable routing tracks and insulation displacement contacts. This intermediary structure facilitates automated cable management and connection, bridging the gap between cable insertion and electrical connection without requiring manual intervention.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If PCB method is used for cable connections, then automated assembly is possible, but the cost increases due to complex production steps, tools, and lack of modularity

Engineering Contradiction:

Improveassembly automationVSAvoidproduction complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent segments the connection system into a modular routing support component that can be independently manufactured and assembled. The routing support with integrated IDC contacts separates the cable management function from the PCB, allowing standardized production tools and reducing overall system complexity while maintaining automation capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The routing support with IDC contacts provides a cost-effective alternative to expensive PCB-based solutions. By using standardized insulation displacement contact technology and simplified cable routing structures, the system reduces production tooling costs and enables modular, adaptable manufacturing without requiring complex specialized equipment.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If PCB method with through-hole pins and connectors is used, then electrical connections can be established, but additional overmoulding is required for mechanical protection and electrical insulation, increasing time and complexity

Engineering Contradiction:

Improveelectrical insulationVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent merges the cable routing function and electrical connection function into a single integrated routing support structure. The routing tracks and IDC contacts are combined in one component, eliminating the need for separate overmoulding steps for mechanical protection and electrical insulation, thereby reducing production time and complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The routing support extracts the cable management and connection function from the PCB assembly process. By taking out the cable routing and connection operations and consolidating them in the routing support with IDC contacts, the patent eliminates time-consuming overmoulding and impregnation steps while maintaining reliable electrical insulation.

Inventive Principle:

Principle #2Taking out (Extraction)

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

Facilitates rapid, reliable, and environmentally friendly production of magnetic bearing modules with reduced error risk, enabling flexible and efficient production across varying dimensions.

Implementation Method 1

an insulation displacement contact

Methodology Applied

Scientific EffectInsulation displacement:

Data Source

PatentUS20250379487A1Radial actuator routing support and associated magnetic bearing module

Publication Date: 2025.12.11 SKF MAGNETIC MECHATRONICS SAS

AI summary

A routing support (1) for a cable (2). The routing support is intended to be assembled onto a radial actuator (4) for a magnetic bearing module (5). The radial actuator (4) for a magnetic bearing module (5) includes an arrangement of coils disposed around a central axis and an insulation displacement contact (7). The routing support (1) includes a routing track for the cable (2) and openings (3) enabling insertion of said cable (2) in the insulation displacement contact (7) through some of the openings (3) when the routing support (1) is positioned facing said radial actuator (4). The routing track is formed on two opposite faces of the routing support (1) by at least one plurality of protuberances and/or serigraphs defining bearing surfaces for said cable (2) for routing it along the routing support (1).