Twisted Cable Structure for Impedance-Based Bend Counting
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Solution Overview
Problem
Cables used for controlling and braking in vehicles, such as automobiles, need to be replaced before wire breakage occurs due to debilitation, and there is a need to count the number of bends applied to the cable to determine the appropriate replacement time.
Innovation Solution
A cable design that includes multiple twisted wire pairs with varying conductor cross-sectional areas, where the twist pitch of the second twisted wire pair is longer than the first, allowing for accurate detection of cable bending by changes in impedance, and enabling the counting of bends to determine the replacement time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cable structure is simplified for ease of manufacture, then manufacturing cost decreases, but the ability to detect bend count is compromised
Solution Approach 1:
The cable core serves multiple functions: it provides structural support for power and signal transmission while simultaneously acting as a bend detection mechanism. The third covered electric wires are integrated into the core structure, allowing the same component to perform both electrical function and mechanical sensing function, eliminating the need for separate detection devices.
Solution Approach 2:
The cable structure itself performs the bend detection function through its inherent design. The change in impedance of the third covered electric wires directly reflects the bend count, allowing the cable to self-monitor its condition without requiring external sensing systems or additional complex detection mechanisms.
2Measurement precision
If multiple wire pairs with different twist pitches are added to detect bend count, then measurement precision improves, but device complexity increases
Solution Approach 1:
Different sections of the cable core have different twist pitches tailored to specific detection requirements. The first twisted wire pair has a shorter twist pitch for general structural stability, while the second twisted wire pair has a longer twist pitch optimized for bend detection sensitivity. This localized differentiation allows precise bend detection without requiring complete redesign of the entire cable structure.
Solution Approach 2:
The invention utilizes changes in electrical impedance parameters of the third covered electric wires to detect bend count. By monitoring the impedance change caused by variations in the physical state of the wires during bending, the system converts mechanical deformation into an electrical signal that can be easily measured and counted, simplifying the overall detection mechanism.
3Measurement precision
If the third covered electric wires are used as bend detection lines with longer twist pitch, then bend detection accuracy improves, but manufacturing precision requirements increase
Solution Approach 1:
The third covered electric wires are pre-configured with a longer twist pitch during manufacturing to optimize their bend detection capability. This preliminary design decision ensures that when the cable is installed and subjected to bending, the wires will exhibit measurable impedance changes that accurately reflect the bend count, allowing the system to be calibrated and optimized before actual use.
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 cable design allows for precise detection of bending and accurate counting of bends, enabling timely replacement of the cable before breakage occurs, thus ensuring continuous functionality and safety.
Implementation Method 1
the bending of the cable may be detected by a change in the impedance of the two third covered electric wires
Data Source
AI summary
A cable includes a plurality of covered electric wires and an outer sheath, wherein the plurality of covered electric wires include two first covered electric wires, two second covered electric wires having a larger conductor cross-sectional area than the first covered electric wires, and two third covered electric wires having a smaller conductor cross-sectional area than the second covered electric wires, and wherein the two first covered electric wires are twisted together along a longitudinal direction thereof to form a first twisted wire pair, the two third covered electric wires are twisted together along a longitudinal direction thereof to form a second twisted wire pair, a twist pitch of the second twisted wire pair is longer than a twist pitch of the first twisted wire pair, the first twisted wire pair, the two second covered electric wires, and the second twisted wire pair are twisted together to form a core, in the core, at least a partial contact is provided between the first covered electric wires and the second covered electric wires, between the second covered electric wires and the third covered electric wires, and between the two first covered electric wires, and the outer sheath is arranged to cover the core.