Composite Cable Spiral Twisting for Smaller, Bend-Resistant Harnesses
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Solution Overview
Problem
Conventional composite cables with multiple power and signal lines have a large outer diameter due to the twisting of signal lines, which limits their bending endurance and disconnection resistance, especially when connected to moving parts.
Innovation Solution
A composite cable design where power lines and signal lines are twisted together inside a sheath, with the signal lines twisted in a spiral shape around a central axis, reducing the overall diameter and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If signal lines are twisted together to reduce crosstalk, then signal transmission quality is improved, but the outer diameter of the cable increases
Solution Approach 1:
The patent applies nesting by placing multiple twisted pair signal lines inside a common shielding structure. Each twisted pair is nested within the electromagnetic field shield, and multiple pairs are nested within the same cable cross-section, allowing compact arrangement while maintaining signal integrity through the shielding effect.
Solution Approach 2:
The patent merges multiple signal lines into a single composite cable structure with unified shielding. Instead of separate cables for each signal pair, multiple twisted pairs are combined within one cable with a common shield, reducing overall diameter while maintaining individual pair isolation for crosstalk prevention.
2Strength
If cable outer diameter is reduced to improve bending endurance, then flexibility is improved, but signal line twisting becomes difficult
Solution Approach 1:
The nested structure allows compact packaging of twisted pairs within a small diameter cable. By nesting signal lines within the shielding structure and arranging them in a compact cross-section, the cable achieves small outer diameter while maintaining the necessary twisting for signal integrity.
Solution Approach 2:
The patent transitions from planar side-by-side arrangement of signal lines to a three-dimensional nested configuration. Multiple twisted pairs are arranged in layers or concentric patterns within the cable cross-section, utilizing vertical space to reduce overall diameter while maintaining twist integrity.
3Adaptability or versatility
If multiple power lines and signal lines are bundled together, then connectivity is improved, but cable diameter increases
Solution Approach 1:
The patent merges power lines and multiple signal pairs into a single composite cable assembly. All conductors share common routing and a unified shielding structure, consolidating what would otherwise require multiple separate cables into one compact unit with improved versatility.
Solution Approach 2:
The cable structure nests signal pairs within the electromagnetic shield, and positions power lines in relation to the signal pairs within the same cross-sectional area. This nested arrangement accommodates multiple functions (power and signal) without proportionally increasing cable diameter.
Data Source
AI summary
A composite cable includes a plurality of power lines for supplying an operating power source to a device to be controlled; a plurality of first signal lines for transmitting control signals for controlling the device to be controlled; a plurality of second signal lines for transmitting detection signals of a sensor for detecting a physical quantity; and a sheath collectively covering the plurality of power supply lines, the plurality of first signal lines, and the plurality of second signal lines, wherein a signal line section in which the plurality of first signal lines and the plurality of second signal lines are twisted together and the plurality of power lines are twisted together inside the sheath, and the plurality of first signal lines and the plurality of second signal lines are twisted together in a spiral shape all together around a central axis of the signal line section.