Remote Control Cable Core Element Design for High Tension

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Solution Overview

Problem

Current core elements for remote control assemblies, used in applications like automotive and marine vehicles, fail to withstand high tension, compression, and fatigue limits, and are costly and time-consuming to manufacture due to complex designs.

Innovation Solution

A core element design featuring a central wire surrounded by outer and intermediate wires, with specific diameter ratios, that collectively define a core element diameter, allowing for higher strength and fatigue resistance while simplifying construction and reducing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If current core element designs are used to meet tension, compression, and fatigue limits, then the cable can withstand certain loads, but the manufacturing becomes expensive and time-consuming

Engineering Contradiction:
Improvetension, compression, and fatigue limitsVSAvoidmanufacturing cost and time
Core Design Contradiction:
StrengthVSEase of manufacture

Solution Approach 1:

The core element is segmented into three distinct wire groups: a central wire (first group), intermediate wires (second group), and outer wires (third group). Each group serves a specific structural function and is positioned at a different radial distance from the central axis. This segmentation allows optimization of each wire group's diameter and material properties to meet strength requirements while simplifying the overall manufacturing process through modular construction.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

Different wire groups are assigned different diameters and material characteristics based on their local structural requirements. The central wire has the largest diameter to provide core stability, intermediate wires have medium diameters for structural support, and outer wires have the smallest diameters for flexibility and surface protection. This local quality differentiation optimizes the strength-to-manufacturing-complexity ratio by placing material where it is most needed.

Inventive Principle:
Principle #3Local quality

2Ease of manufacture

If a simpler core element construction is used to ease manufacturing and reduce costs, then manufacturing becomes easier and cheaper, but the cable cannot withstand high tension, compression, and fatigue limits

Engineering Contradiction:
Improvemanufacturing simplicity and costVSAvoidtension, compression, and fatigue limits
Core Design Contradiction:
Ease of manufactureVSStrength

Solution Approach 1:

The core element is segmented into three distinct wire groups: a central wire (first group), intermediate wires (second group), and outer wires (third group). Each group serves a specific structural function and is positioned at a different radial distance from the central axis. This segmentation allows optimization of each wire group's diameter and material properties to meet strength requirements while simplifying the overall manufacturing process through modular construction.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent merges three different wire configurations (central wire, intermediate wires, and outer wires) into a single integrated core element structure. This combination creates a synergistic effect where the central wire provides core strength, intermediate wires provide structural support, and outer wires provide surface protection and flexibility, collectively achieving high tension, compression, and fatigue resistance.

Inventive Principle:
Principle #5Merging (Combining)

3Strength

If the diameter ratios of central wire, outer wires, and intermediate wires are optimized, then the core element achieves proper tension, compression, and fatigue limits, but the design complexity increases

Engineering Contradiction:
Improvetension, compression, and fatigue limitsVSAvoiddesign complexity
Core Design Contradiction:
StrengthVSDevice complexity

Solution Approach 1:

The patent specifies precise diameter ratios as key parameters: the central wire diameter is 41.5%-43.5% of the core element diameter, intermediate wire diameter is 10.5%-10.7%, and outer wire diameter is 17.5%-18.5%. These parameter optimizations ensure that each wire group contributes appropriately to the overall strength while maintaining manufacturability. By establishing these specific parameter ranges, the design achieves high strength without excessive complexity.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentEP3184830B8Cable of a remote control assembly
Publication Date: 2018.10.24 KONGSBERG POWER PROD SYST I INC

AI summary

A cable (20) of a remote control assembly (10) includes a conduit (11) defining an interior and a length, and a core element (18) disposed within the interior of the conduit. The core element (18) has a central wire (24) extending along a longitudinal axis. The central wire (24) defines a first diameter D1 and a length extending along the longitudinal axis. The core element (18) also includes a plurality of outer wires (28) surrounding and coupled to the central wire (24) along the length. Each of the outer wires (28) define a second diameter D2 less than the first diameter D1. The core element (18) further includes a plurality of intermediate wires (30) surrounding and coupled to the central wire (24) along the length and coupled to the plurality of outer wires (28) along the length. The plurality of intermediate wires (30) is sandwiched between both the central wire (24) and the plurality of outer wires (28). Each of the intermediate wires (30) defines a third diameter D3 less than the second diameter D2.