Flat Cable Harness For Vehicle

Mr Antti Backman, Chief Design Officer, New Cable Corporation writes about the effect Flat Cable Harness has on radio controlled vehicles:

“I have played around with radio controlled (RC) vehicles for few tens of years. For a long time I thought that these cars, tanks and aeroplanes are crappy; brushed electric motors and small combustion motors combined to Megahertz frequency range radio controls with modest transmission power. Within last ten years I have had to change my opinion on these devices, that have turned to magnificent pieces of gadgets and I love those.

Technology development has brought brushless motors and lithium-polymer batteries along with powerful Gigahertz frequency range radio controls to these devices. One thing has still been bothering me. The cables and the connectors. Especially the connectors have been annoying as the high amperage cables require sufficient connection. These connectors tend to be very bulky and difficult to use. One problematic thing with these cables and connectors is the heat generated by the high amperage. The cooling after the usage is also very slow.

When we introduced Shielded Flat Flexible Cables (SFFC) in 2016 we had plans to use those not only in automation electronics but also in vehicles. The last two years have been more than hectic, I have bought drones and learned how to fly with them. While assembling the drones I noted that it would be quite cool to use SFFC also on flying things. I had already “flattened” one RC car and the second one was even more integrated in terms of cable harnesses.

The first “flattened” car on the left. The individual flat cables are pushing maximum 120 amperes through. These cars were presented at IDTechEx Berlin 2018

The “more flattened” RC car was introduced to premium car manufacturers during the late autumn. I was quite happy to learn how the engineers and the designers were surprised about the weight difference the two RC car cabling had (we had also the “stock” car with round cables with us). The round cable set weighted 25 grams and our custom made flat harness 2 grams. We gave the opportunity for the designers and the engineers to drive these cars and after each “race” I noted the long lasting heat from the round cable car.

Here is the “more flattened” RC car. On the left are the removed round cables that weigh 25 grams and in the forefront the the flat cable harness that weigh 2 grams. The motor cabling is separate just to show what are the possibilities with flat cables. Flat connectors (green) can be seen on the car.

I have to admit that I am very thrilled from that late autumn event. In real size vehicles our cables really make the difference. It seems that we are going to save the world, one cable at a time.

Mr Antti Backman, Chief Design Officer, New Cable Corporation

P.S. Modern Megahertz radios are actually very nice, thanks to softwares and transmission power. Huge distances. ;-)”