Rotating Cable Protector for Flat Cables in Aerospace Link Assemblies
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Solution Overview
Problem
Cables used in aerospace applications that move relative to each other experience fatigue due to repeated flexing, leading to unacceptable damage over their lifetime, and existing cable protectors are inefficient in managing the stress and space requirements for flat or strip-form cables.
Innovation Solution
A cable protector design featuring a cup and lid that rotate relative to each other, with a winding chamber that accommodates a flat or strip-form cable, allowing for a planar roll configuration that reduces the width and depth of the chamber, and includes a cable guide and securing mechanisms to manage the cable's width and thickness ratio, enabling efficient routing and stress reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a traditional cable protector design is used, then the cable can be protected from damage, but the winding chamber requires excessive width and depth, resulting in inefficient space utilization
Solution Approach 1:
The cable protector employs a dynamic rolling mechanism where the cable is wound into a compact roll within the winding chamber. The cable can be dynamically wound and unwound as the cup and lid rotate relative to each other, allowing the same chamber volume to accommodate varying cable lengths while maintaining compact dimensions. This dynamic approach reduces the required static volume compared to fixed winding designs.
Solution Approach 2:
The invention utilizes the rotational dimension between the cup and lid to create a three-dimensional winding space. By allowing rotation around a pivot axis, the cable can be wound in a compact roll configuration that efficiently uses the available volume, transforming a potentially large linear space into a compact radial winding chamber.
2Duration of action of moving object
If the cable is routed through a large winding chamber, then the cable has more space to accommodate flexing, but the overall device size increases
Solution Approach 1:
The dynamic rolling mechanism allows the cable to be compactly stored when not in use and smoothly deployed when needed. The rotation between cup and lid enables the cable to flex and move dynamically, extending cable lifespan through controlled motion while keeping the protector footprint small.
Solution Approach 2:
The cable is nested within the winding chamber in a compact roll configuration. The cup and lid structure contains the cable roll, creating a nested arrangement where the cable is efficiently packed within the minimal required space, reducing the overall device footprint while maintaining cable flexibility.
3Force
If the cable width is significantly greater than its thickness, then the cable can handle higher loads, but the winding chamber requires larger dimensions to accommodate the cable
Solution Approach 1:
The invention exploits the width-thickness dimension ratio by winding the wide, thin cable into a compact roll. The rotation around the pivot axis allows the cable to be wound perpendicular to its width, creating a compact cylindrical roll that efficiently accommodates the wide cable in minimal volume.
Solution Approach 2:
The dynamic rolling mechanism allows the wide cable to be compactly wound and stored. The rotation between cup and lid enables efficient packing of the wide cable into a compact roll, reducing the required chamber volume while maintaining the cable's load-bearing width when deployed.
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 effectively reduces the side-to-side width and end-to-end depth of the winding chamber, allowing for a more compact and stress-reduced cable routing system that can accommodate cables with a high width-to-thickness ratio, thereby extending the cable's lifespan and improving operational reliability.
Implementation Method 1
a lid which defines a second end of the winding chamber opposite to the first end, wherein the lid is coupled to the cup by a bearing so that the cup and lid can rotate with respect to each other
Data Source
Figure 1~3
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AI summary
A link assembly has a pair of mechanical links pivotally connected to rotate relative to one another about a pivot axis. A cable protector is provided as part of the link assembly. The cable protector has a cup with an end wall which defines a first end of a winding chamber, and an annular side wall which extends from the end wall and defines a side of the winding chamber. A lid defines a second end of the winding chamber opposite to the first end. The lid is coupled to the cup by a bearing so that the cup and lid can rotate with respect to each other. An opening is formed in the side wall of the cup and a slot is formed in the lid. The assembly is fitted with a cable having a length, a width, and a thickness, wherein the width of the cable is greater than its thickness. The cable has a first portion which extends along a first one of the links and passes into the side of the winding chamber through the opening in the side wall of the cup, a second portion which extends along a second one of the links and passes into the second end of the winding chamber through the slot in the lid, and a rolled portion in the winding chamber in which the cable is wound into a roll, the roll including an outer turn which leads to the first portion and an inner turn which is inside the outer turn and leads to the second portion.