Shielded Multi-Wire Cable Assembly for Automated EMI Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing cable assemblies, particularly for multi-electrode catheters, face challenges in efficiently twisting and shielding multiple wires from Electromagnetic Interference (EMI) while maintaining proper tension and automation.
Innovation Solution
A system and method for manufacturing shielded cable assemblies that involves gripping pre-assembled cable assemblies with fixtures, maintaining wire tension using a stretching device, twisting the wires with a rotation device, and applying an electromagnetic shield using a shielding device, all within a fully automated process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multiple wires are passed through a small-diameter catheter shaft, then the cable assembly fits within the catheter, but the wires are susceptible to Electromagnetic Interference (EMI)
Solution Approach 1:
The electromagnetic shield is nested around the bundle of wires, creating a protective enclosure that fits within the constrained catheter shaft diameter while providing EMI shielding. The shield acts as an intermediate layer between the wires and the external electromagnetic environment.
Solution Approach 2:
The electromagnetic shield converts the harmful EMI into a controlled electrical signal path by providing a grounded conductive barrier that redirects electromagnetic interference away from the signal-carrying wires, transforming potential noise into a manageable grounding current.
2Stability of the object's composition
If wires are twisted to maintain proper tension and organization, then the cable assembly structure is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The wires are pre-twisted and pre-tensioned using a twisting mechanism before the electromagnetic shield is applied. This preliminary action ensures proper wire organization and tension is established prior to shielding, simplifying the overall manufacturing process by separating the twisting operation from the shielding operation.
Solution Approach 2:
The manufacturing system employs dynamic control of the twisting mechanism, allowing the wires to be twisted to a predetermined angle and tension level. This dynamic adjustment capability enables precise control of wire organization while maintaining manufacturing efficiency through automated feedback control.
3Object-affected harmful factors
If an electromagnetic shield is applied around the wires, then EMI protection is improved, but the manufacturing time and process complexity increase
Solution Approach 1:
The electromagnetic shield is applied in a preliminary manner around the already-twisted wire bundle, rather than attempting to twist wires after shielding. This sequence optimization reduces manufacturing time by eliminating the need to disassemble the shield for twisting operations.
Solution Approach 2:
The shielding application process is merged with the cable assembly formation process, where the shield is applied as an integral step in the overall manufacturing sequence. This integration allows simultaneous completion of shielding and cable structuring operations, reducing total manufacturing cycle time.
Data Source
AI summary
A method includes providing a pre-assembled cable assembly including a plurality of wires and a circuit board. The pre-assembled cable assembly has a first end and a second end, and the wires are connected to the circuit board at the second end. The pre-assembled cable assembly is gripped at the first end and at the second end. While the pre-assembled cable assembly is gripped, an electromagnetic shield is applied around the wires.