Rotary Connector Cable Routing via Equipotential Lead Blocks
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Solution Overview
Problem
Existing rotary connectors in steering devices require complicated three-dimensional bending of cables, leading to unnecessary stress and difficulty in automated assembly, as the cable ends are not positioned at the same height along the rotation center line, causing friction and potential damage.
Innovation Solution
A rotary connector design where the cable is wound around the rotation center line without bending, with movable and fixed lead blocks positioned at the same height, allowing the cable to circulate smoothly and reducing stress, and a manufacturing method that simplifies assembly by fixing these blocks simultaneously with the cable, enabling automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cable is three-dimensionally bent to connect the annular space and lead block positioned at different heights, then the cable can be connected between separated components, but the assembly operation becomes complicated and unnecessary stress is applied to the cable
Solution Approach 1:
The patent positions the annular space and lead block at the same height level, creating an equipotential arrangement that eliminates the need for vertical cable routing. This allows the cable to be connected in a straight line without three-dimensional bending, simplifying assembly operations and avoiding unnecessary stress on the cable while maintaining electrical connectivity between components
2Reliability
If the cable is three-dimensionally bent to extract from the annular space, then the cable can reach the lead block, but excessive friction force may damage the cable during rotation
Solution Approach 1:
By positioning the lead block at the same height as the annular space, the cable exits the annular space horizontally without vertical bending. This creates a smooth, stress-free path that minimizes friction during rotation, preventing cable damage and ensuring reliable operation while maintaining electrical connectivity
3Extent of automation
If the cable is three-dimensionally bent in the annular space, then the cable can be connected to vertically separated components, but automated assembly becomes difficult
Solution Approach 1:
The patent aligns the annular space and lead block at the same height, transforming the cable routing from a complex three-dimensional bending operation into a simple linear connection. This simplification enables automated assembly machines to perform cable installation efficiently without requiring complex positioning or bending mechanisms, while ensuring reliable electrical connectivity
Data Source
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AI summary
Movable end portions of cables (2 and 3) are fixed to a movable lead block (30), and fixed end portions of the cables (2 and 3) are fixed to a fixed lead block (40). The movable lead block (30) is mounted so as to be inserted into a cylindrical portion (12) of a rotary body (10) in a direction along a rotation center line (O), and the fixed lead block (40) is mounted so as to be inserted into a lead block attachment portion (23) of a lower housing (20) in the direction along the rotation center line (O). The movable end portions and the fixed end portions of the cables (2 and 3) are positioned at the same heights as those of the cables (2 and 3) in a wiring space (S).