Single Sheath Cable Structure for Multi-Tool Power and Data Routing
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Solution Overview
Problem
The complexity and cost associated with wiring multiple electrically powered manufacturing tools in a multi-tool process machine, due to the large number of cables required for power and data transmission, complicate installation and maintenance.
Innovation Solution
A cable structure with a single outer sheath supplies power and data to multiple tools, using a single continuous or segmented cable with flexible portions near the tools, and optionally a distribution block, reducing the number of cables and incorporating both electrical and optical conductors for efficient signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple individual cables are used to connect the voltage source to each tool, then reliable power and data transmission is achieved, but the wiring complexity and installation cost increase significantly
Solution Approach 1:
The patent combines multiple separate cables (power cables and data cables) into a single integrated cable structure that serves multiple tools simultaneously. This cable structure contains multiple conductors arranged in a specific pattern, allowing it to carry both power and data signals to multiple tools through a single physical connection, thereby reducing wiring complexity while maintaining transmission reliability
Solution Approach 2:
The cable structure is designed to perform multiple functions: it provides power transmission to multiple tools, carries data signals for communication, and incorporates shielding for noise protection. This multi-functional design eliminates the need for separate dedicated cables for each function, resolving the contradiction between reliability and complexity
2Reliability
If multiple separate cables are used for power and data connections, then adequate shielding and signal integrity are maintained, but installation and maintenance time increase
Solution Approach 1:
The patent merges power conductors and data conductors into a single cable assembly with integrated shielding structures. The cable structure includes shielding elements positioned between conductors to maintain signal integrity, while the unified design reduces the number of connection points from multiple separate cable installations to a single installation operation, significantly reducing installation and maintenance time
3Device complexity
If a single cable structure is used to supply power to multiple tools, then cable complexity and cost are reduced, but the cable must span a significant distance from the voltage source
Solution Approach 1:
The patent segments the cable structure into multiple sections with specific conductor arrangements in different zones. The cable structure includes a first section with a first pattern of conductors and a second section with a second pattern, allowing optimization for different functional requirements along the cable length. This segmentation enables the cable to efficiently manage power distribution over long distances while maintaining structural organization
Data Source
AI summary
A multi-tool process station includes a tool sub-station having a plurality of electrically powered tools moveable between an operating position and a ready position; a voltage source spaced therefrom by a distance; at least one controller spaced from the tool sub-station and in communication with the tools; a cable structure extending across the distance and having not more than one outer cable sheath at any point along the distance, the cable structure supplying power from the voltage source to a plurality of the tools and further carrying control signals to the plurality of tools. The cable structure may consist of a single continuous cable, or may comprise multiple cable segments, such as first and second cables connected in series. The tool sub-station may be disposed proximate a vehicle manufacturing line and the plurality of tools comprise at least a plurality of screw spindles.