Noise and vibration reducing flex-cable assembly
View Patent ↗A flexible drive cable assembly for powered adjustable pedals includes an elongate flexible casing having a unitary connector which cooperates with an end fitting to secure the casing to the end fitting and hold the casing stationary relative to the end fitting. In one embodiment, the unitary connector and the end fitting form a snap-fit connection having both an interlock and an interference fit between the casing and the end fitting to reduce vibration. In another embodiment, the casing is heat staked to the end fitting such that casing material flows into grooves to form protrusions which interlock with the end fitting and an interference fit between the casing and the end fitting to reduce vibration. In another embodiment, the unitary connector includes an elongate portion press fit into an aperture of the end fitting and a flange engaging the end fitting adjacent the aperture.
1. An adjustable pedal assembly comprising, in combination:
a flexible drive cable assembly comprising:
an elongate flexible core for transmitting movement from a first end of the core to a second end of the core;
an elongate flexible casing encircling a longitudinal length of the core and having a preformed unitary connector at one end; and
wherein the first end of the core has a first connection and the second end of the core has a second connection and the casing extends along the longitudinal length of the core from the first connection of the core to the second connection of the core;
an end fitting having an aperture for passage of the core therethrough;
wherein the unitary connector of the casing cooperates with the end fitting to secure the casing to the end fitting and hold the casing stationary relative to the end fitting;
an electric motor operably connected to the core for transmission of movement therebetween;
at least one drive screw operably connected to the core for transmission of movement therebetween; and
wherein the flexible drive cable assembly connects the electric motor and the drive screw such that operation of the electric motor rotates the drive screw.
2. The adjustable pedal assembly according to claim 1 , wherein the unitary connector of the casing and the end fitting form a snap-fit connection.
3. The adjustable pedal assembly according to claim 2 , wherein the unitary connector of the casing comprises a deflectable protrusion interlocking with the end fitting to secure the casing to the end fitting.
4. The adjustable pedal assembly according to claim 3 , wherein the protrusion forms an interference fit with the end fitting to reduce vibration therebetween.
5. The adjustable pedal assembly according to claim 2 , wherein the unitary connector of the casing comprises a protrusion disposed radially outward and generally encircling an outer circumference of the casing, the aperture of the end fitting opens into a passage having a protrusion disposed radially inward and generally encircling an inner circumference of the passage, and the casing extends into the passage with the protrusion of the casing interlocking with the protrusion of the end fitting to secure the casing to the end fitting.
6. The adjustable pedal assembly according to claim 1 , wherein the unitary connector of the casing comprises a protrusion disposed radially outward and generally encircling an outer circumference of the casing, the aperture of the end fitting opens into a passage having a protrusion disposed radially inward and generally encircling an inner circumference of the passage, and the casing extends into the passage with the protrusion of the casing interlocking with the protrusion of the end fitting to secure the casing to the end fitting.
7. The adjustable pedal assembly according to claim 1 , wherein the end fitting has an elongated portion with an outer surface, the outer surface of the elongated portion has at least one groove formed therein, the casing has generally coaxial inner and outer surfaces, the casing extends over the elongated portion with the inner surface of the casing engaging the outer surface of the elongated portion, and the casing has at least one protrusion extending from the inner surface of the casing and into the groove of the elongated portion to interlock the casing with the end fitting.
8. The adjustable pedal assembly according to claim 7 , wherein the protrusion is formed by heat staking the casing at the elongated connector.
9. The adjustable pedal assembly according to claim 1 , wherein the unitary connector comprises an elongated portion having a generally cylindrically shaped outer surface extending through the aperture of the end fitting and a flange extending generally perpendicular to the outer surface of the elongated portion and engaging the end fitting adjacent the aperture of the end fitting.
10. The adjustable pedal assembly according to claim 9 , wherein the outer surface of the elongated portion forms a press fit with the aperture of the end fitting.
11. The adjustable pedal assembly according to claim 1 , wherein the unitary connector comprises an elongated portion having a generally cylindrically shaped outer surface extending through the aperture of the end fitting and forms a press fit with the aperture of the end fitting.
12. An adjustable pedal assembly comprising, in combination:
a flexible drive cable assembly comprising:
an elongate flexible core for transmitting movement from a first end of the core to a second end of the core; and
an elongate flexible casing encircling a longitudinal length of the core and having a preformed, unitary connector with at least one deflectable protrusion;
an end fitting having an aperture for passage of the core therethrough;
wherein the connector of the casing and the end fitting form a snap-fit connection to secure the casing to the end fitting and hold the casing stationary relative to the end fitting and the deflectable protrusion of the connector engages the end fitting with an interference fit such that the deflectable protrusion is in an unrelaxed state to reduce vibration between the casing and the end fitting;
an electric motor operably connected to the core for transmission of movement therebetween;
at least one drive screw operably connected to the core for transmission of movement therebetween; and
wherein the flexible drive cable assembly connects the electric motor and the drive screw such that operation of the electric motor rotates the drive screw.
13. The adjustable pedal assembly according to claim 12 , wherein the interference fit is in a direction transverse to a longitudinal axis of the casing.
14. The adjustable pedal assembly according to claim 12 , wherein the deflectable protrusion is disposed radially outward and generally encircles an outer circumference of the casing, the aperture of the end fitting opens into a passage having a protrusion disposed radially inward and generally encircling an inner circumference of the passage, and the casing extends into the passage with the deflectable protrusion of the casing interlocking with the protrusion of the end fitting to secure the casing to the end fitting.
15. An adjustable pedal assembly comprising, in combination:
a flexible drive cable assembly comprising:
an elongate flexible core for transmitting movement from a first end of the core to a second end of the core; and
an elongate flexible casing encircling a longitudinal length of the core and having generally coaxial inner and outer surfaces;
an end fitting having an elongated portion with an outer surface and an aperture for passage of the core therethrough, the outer surface of the elongated portion having at least one groove formed therein;
wherein the casing has a preformed enlarged cylindrically-shaped end portion forming an end surface of the casing and having an inner diameter closely receiving the elongated portion of the end fitting;
wherein the casing has at least one protrusion extending from the inner surface of the casing and into the groove of the elongated portion to interlock the casing with the end fitting and to hold the casing stationary relative to the end fitting;
an electric motor operably connected to the core for transmission of movement therebetween;
at least one drive screw operably connected to the core for transmission of movement therebetween; and
wherein the flexible drive cable assembly connects the electric motor and the drive screw such that operation of the electric motor rotates the drive screw.
16. The adjustable pedal assembly according to claim 15 , wherein the protrusion is formed by heat staking the casing at the elongated connector.
17. The adjustable pedal assembly according to claim 15 , wherein the outer surface of the elongated surface has a plurality of grooves and the casing has a plurality of protrusions extending into the grooves.
18. An adjustable pedal assembly comprising, in combination:
a flexible drive cable assembly comprising:
an elongate flexible core for transmitting movement from a first end of the core to a second end of the core;
an elongate flexible casing encircling a longitudinal length of the core and having a connector; and
wherein the connector comprises a preformed, unitary enlarged end portion having a generally cylindrically shaped outer surface and a flange extending generally perpendicular to the outer surface of the elongated portion;
an end fitting having an aperture for passage of the core therethrough;
wherein the outer surface of the connector extends through the aperture of the end fitting and the flange of the connector engages the end fitting adjacent the aperture of the end fitting to secure the casing to the end fitting and to hold the casing stationary relative to the end fitting;
an electric motor operably connected to the core for transmission of movement therebetween;
at least one drive screw operably connected to the core for transmission of movement therebetween; and
wherein the flexible drive cable assembly connects the electric motor and the drive screw such that operation of the electric motor rotates the drive screw.
19. The adjustable pedal assembly according to claim 18 , wherein the outer surface of the enlarged end portion forms a press fit with the aperture of the end fitting.
20. The adjustable pedal assembly according to claim 18 , wherein the enlarged end portion of the connector forms a journal for supporting an end of one of the electric motor and the drive screw.