Rotatable Connector Dummy Cable Protection
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Solution Overview
Problem
Existing rotatable connector devices for vehicles are prone to malfunction when contaminated with foreign objects like sand, as the flat cable can be abraded, leading to electrical disconnection between the rotator and stator.
Innovation Solution
Incorporating a flexible and elastic dummy cable that non-electrically connects the rotator and stator, which can rotate with the retainer even when contaminated, maintaining electrical connection by reversing its winding direction and using repulsive power to prevent buckling and ensure smooth operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the flat cable is used to electrically connect the rotator and stator, then electrical connection is achieved, but the flat cable can be abraded by foreign objects causing malfunctioning
Solution Approach 1:
The dummy cable serves as an intermediary element between the rotator and stator. It is positioned to contact the press guide and rotatable rollers instead of the flat cable, thereby mediating the mechanical interaction and protecting the flat cable from direct contact with foreign objects. The dummy cable absorbs the abrasion and contamination effects, allowing the flat cable to maintain its electrical connection function without direct exposure to harmful factors.
Solution Approach 2:
The dummy cable is designed as a copy or replica of the flat cable in terms of its structural form and winding path, but without the electrical conductive function. It replicates the cable's physical configuration and interaction with the retainer mechanism, allowing it to perform the protective function while the unique electrical function remains with the flat cable. This copying approach allows the system to separate the protective and electrical functions.
2Ease of operation
If the retainer rotates to assist cable winding, then smooth rotation is achieved, but the reversed part of the flat cable contacts the press guide and may be abraded
Solution Approach 1:
The dummy cable acts as a mediator that takes over the contact role with the press guide during retainer rotation. When the retainer rotates to assist cable winding, the dummy cable's reversed part contacts the press guide instead of the flat cable's reversed part. This intermediary action maintains the smooth rotation function while eliminating the harmful abrasion effect on the electrically critical flat cable.
3Adaptability or versatility
If the flat cable is made to wind and rewind in the accommodation space, then electrical connection during rotation is maintained, but contamination causes abrasion and malfunctioning
Solution Approach 1:
The cable system is segmented into two distinct functional components: the flat cable responsible for electrical connection and the dummy cable responsible for mechanical protection. This segmentation allows each component to be optimized for its specific function. The flat cable can be designed with focus on electrical properties while the dummy cable handles the mechanical wear and contamination exposure, thereby maintaining both rotation adaptability and electrical connection reliability.
Solution Approach 2:
The dummy cable serves as a protective intermediary that shields the flat cable from contamination during the winding and unwinding process. As the retainer rotates and the cables wind and rewind in the accommodation space, the dummy cable is positioned to contact the press guide and rollers first, creating a protective barrier that prevents foreign objects from reaching the flat cable and causing abrasion that would compromise electrical connection reliability.
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
The solution ensures reliable electrical connection between the rotator and stator even when contaminated, preventing damage to the flat cable and maintaining smooth operation by using the dummy cable's elasticity and strategic placement to avoid contact with restriction sections.
Implementation Method 1
a flexible and elastic dummy cable having one end in a longitudinal direction thereof connected and fixed to the side of the rotator and the other end thereof connected and fixed to the side of the stator
Implementation Method 2
a retainer 40 provided on a bottom surface of an accommodation space and guides the flat cable to be wound around a rotation axis of the steering wheel
Data Source
AI summary
In an accommodation space formed by a rotator and a stator, a flat cable and a dummy cable are accommodated. A retainer placed in a bottom part of the accommodation space is provided with a press guide for allowing a reversed part of the dummy cable, at which a winding direction thereof is reversed, to be pressed thereon.