Cable mechanism for electric vehicle charging station

Abstract

The cable mechanism releases and withdraws a cable having a free end and a fixed end. The cable mechanism includes a motor assembly for engaging a guide portion of a cable to release or retract the cable and a pulley assembly for engaging a following portion of the cable. The following portion may be disposed between the guide portion and the fixed end of the cable. The pulley assembly is movable relative to the motor assembly between a first position and a second position. Moving the pulley assembly from the first position to the second position releases the cable, and moving the pulley assembly from the second position to the first position withdraws the cable.

Description

Cross - Reference to Related Applications

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 375,286, filed on September 12, 2022, the entire content of which is incorporated herein by reference. Background Art

[0002] The present disclosure relates to a motorized cable mechanism, and more particularly, to a motorized cable mechanism for releasing and retracting a cable for electric vehicle charging. Background Art

[0003] Cables are used to complete various types of circuits, and since the distance between a power source and a rechargeable device can vary, cables help connect the power source to the rechargeable device (such as an electric vehicle (EV)). Although relatively long cables are typically required to increase the possible distance between the power source and the rechargeable device, such long cables can be inconvenient to store or use when a shorter length of cable is needed. Additionally, it is generally difficult to expect a user to neatly stow a loose cable after use.

[0004] Cables can be managed by winding them around a spool, where the spool can be rotated to release or retract the desired length of cable. However, a spool may require a slip ring to maintain connection to the power source. Due to cost, reliability, or environmental factors, slip rings may not be feasible in high - voltage or high - current situations. When applied to an active circuit, coiled cables also pose additional problems because tightly coiled cables generate heat in high - current situations. This requires the operating current to be significantly lower than the rated current of the cable. Such problems are particularly prominent in EV charging applications that require high current.

[0005] Accordingly, there is a need for a cable mechanism that can release and retract a cable in a controlled manner and enable storage of the cable. Summary of the Invention

[0006] Embodiments of the present disclosure provide a cable mechanism for releasing and retracting a cable having a free end and a fixed end. The cable mechanism can include a motor assembly for engaging a guiding portion of the cable to release or retract the cable and a pulley assembly for engaging a following portion of the cable. The following portion can be disposed between the guiding portion and the fixed end of the cable. The pulley assembly can move between a first position and a second position relative to the motor assembly. Moving the pulley assembly from the first position to the second position releases the cable, and moving the pulley assembly from the second position to the first position retracts the cable.

[0007] In some embodiments, the cable mechanism can further include a housing. The motor assembly can be disposed within the housing, and the pulley assembly can move vertically within the housing relative to the motor assembly.

[0008] In some embodiments, the housing may be at least partially sealed. The fixed end of the cable may be disposed within the housing, and the free end of the cable may be disposed outside the housing.

[0009] In some embodiments, at a first position, the maximum length of the cable may be disposed within the housing, and at a second position, the minimum length of the cable may be disposed within the housing.

[0010] In some embodiments, the pulley assembly may include a linear motion guide, a sliding carriage movable along the linear motion guide between a first position and a second position, at least one movable pulley disposed on the sliding carriage, and at least one fixed pulley disposed adjacent to the motor assembly. The following portion of the cable may be wound around at least one movable pulley and at least one fixed pulley arranged in sequence.

[0011] In some embodiments, the pulley assembly may further include a drive motor for driving a drive chain. The sliding carriage may be fixed to the drive chain such that when the drive motor drives the drive chain, the sliding carriage may move along the linear motion guide between the first position and the second position.

[0012] In some embodiments, the diameter of at least one movable pulley and at least one fixed pulley is at least 5 times the diameter of the cable.

[0013] In some embodiments, at least one movable pulley and at least one fixed pulley may not be parallel such that the subsequent pulley on each turn of the cable has an input at a position intersecting the plane of the previous pulley arranged in sequence.

[0014] In some embodiments, at least one movable pulley and at least one fixed pulley may include a series of pulleys arranged in an arc. The radius of the arc is at least 5 times the radius of the cable.

[0015] In some embodiments, at least one movable pulley may include a plurality of movable pulleys, and at least one fixed pulley may include a plurality of fixed pulleys. The following portion of the cable may be alternately wound around one of the plurality of movable pulleys and one of the plurality of fixed pulleys arranged in sequence.

[0016] In some embodiments, the motor assembly may include an outlet motor for driving a pair of drive rollers. The guiding portion of the cable may be disposed between the pair of drive rollers such that when the outlet motor drives the pair of drive rollers, the pair of drive rollers may engage the guiding portion of the cable to release or retract the free end of the cable.

[0017] In some embodiments, the motor assembly may further include at least one pair of guiding rollers disposed upstream and / or downstream of the pair of drive rollers. The at least one pair of guiding rollers may be used to change the angular direction in which the cable is released or retracted.

[0018] In some embodiments, the cable mechanism may further include a drive motor for moving the pulley assembly between a first position and a second position, an outlet motor in the motor assembly for releasing or retracting the free end of the cable, and a controller for synchronizing the drive motor and the outlet motor such that when releasing or retracting, the cable maintains tension between the guiding portion and the fixed end.

[0019] In some embodiments, the controller may be configured to control the speed of the drive motor slower than the speed of the outlet motor when the cable is released from the cable mechanism.

[0020] In some embodiments, the controller may be configured to control the speed of the drive motor slower than the speed of the outlet motor when the cable is retracted into the cable mechanism.

[0021] In some embodiments, the cable mechanism may further include a control switch disposed at the free end of the cable. The control switch is in electronic communication with the controller. The control switch may be configured to send an instruction to the controller to release or retract the cable.

[0022] In some embodiments, the control switch may be configured to send an instruction to the controller to release or retract a specific length of the cable.

[0023] Another embodiment of the present disclosure provides a method of releasing or retracting a cable having a free end and a fixed end. The method may include providing a cable mechanism. The cable mechanism may include a motor assembly for engaging a guiding portion of the cable to release or retract the cable, and a pulley assembly for engaging a following portion of the cable, the following portion being disposed between the guiding portion and the fixed end of the cable. The pulley assembly may be movable relative to the motor assembly between a first position and a second position.

[0024] The method may further include moving the pulley assembly from the first position to the second position to release the cable, or moving the pulley assembly from the second position to the first position to retract the cable.

[0025] In some embodiments, moving the pulley assembly from the first position to the second position, or moving the pulley assembly from the second position to the first position may include synchronously controlling a drive motor and an outlet motor of the motor assembly to move the pulley assembly between the first position and the second position and release or retract the free end of the cable such that the cable maintains tension when released or retracted. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] To more fully understand the nature and objects of the present disclosure, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which:

[0027] Figure 1 is a schematic diagram of a cable mechanism according to an embodiment of the present disclosure;

[0028] Figure 2Shows an example cable mechanism according to an embodiment of the present disclosure;

[0029] Figure 3A Shows the example cable mechanism in the first position;

[0030] Figure 3B Shows the example cable mechanism in the second position;

[0031] Figure 4A 、 Figure 4B 、and Figure 4C Shows an example cable mechanism including a detailed view of a pulley assembly;

[0032] Figure 5A and Figure 5B Shows an example cable mechanism including a detailed view of a motor assembly;

[0033] Figure 6A Is a top view schematic diagram of the pulley assembly of the cable mechanism according to an embodiment of the present disclosure;

[0034] Figure 6B Is a top view schematic diagram of the cable wound around the pulley assembly of the cable mechanism according to an embodiment of the present disclosure;

[0035] Figure 6C Is a top view schematic diagram of the cable wound around the pulley assembly of the cable mechanism according to another embodiment of the present disclosure;

[0036] Figure 7 Shows a top view of the pulley assembly of the example cable mechanism;

[0037] Figure 8A Is a top view schematic diagram of the pulley assembly of the cable mechanism according to an embodiment of the present disclosure;

[0038] Figure 8B Is a top view schematic diagram of the pulley assembly of the cable mechanism according to another embodiment of the present disclosure;

[0039] Figure 9A Is a flowchart of a method for releasing or retracting a cable according to an embodiment of the present disclosure; and

[0040] Figure 9B Is a flowchart of a method for releasing or retracting a cable according to another embodiment of the present disclosure. Detailed Description

[0041] While the subject matter claimed in this disclosure will be described with respect to specific embodiments, other embodiments, including embodiments that do not recite all of the advantages and features described herein, are within the scope of this disclosure. Various modifications may be made to the structure, logic, process steps, and electronic components without departing from the scope of this disclosure. Accordingly, the scope of this disclosure is defined only by the appended claims.

[0042] As Figure 1 shown, one embodiment of the present disclosure provides a cable mechanism 100 for releasing and retrieving a cable 101. The cable 101 may have a free end 102 and a fixed end 105. The cable mechanism 100 may include a motor assembly 110 for engaging a guiding portion 103 of the cable 101 to release or retrieve the cable 101 and a pulley assembly 120 for engaging a following portion 104 of the cable. The following portion 104 may be disposed between the guiding portion 103 and the fixed end 105 of the cable 101. The pulley assembly 120 may be movable between a first position and a second position relative to the motor assembly 110. When the pulley assembly 120 moves from the first position to the second position, the cable 101 is released, and when the pulley assembly 120 moves from the second position to the first position, the cable 101 is retrieved. By moving the pulley assembly 120 when the motor assembly 110 releases or retrieves the cable 101, the cable 101 can maintain tension among the guiding portion 103, the following portion 104, and the fixed end 105, enabling the cable mechanism 100 to operate smoothly.

[0043] It should be understood that during the use of the cable mechanism 100, the guiding portion 103 and the following portion 104 may refer to different portions of the cable 101. For example, since the specific portion of the cable 101 that engages with the motor assembly 110 continuously changes as the cable 101 passes through the motor assembly 110, the guiding portion 103 of the cable 101 may change as the cable 101 is released or retrieved. Since the length of the cable 101 that engages with the pulley assembly 120 changes between the first position and the second position, the following portion 104 may also change as the cable 101 is released or retrieved. Therefore, the guiding portion 103 and the following portion 104 of the cable 101 shown in the drawings refer to specific instances in different states of the cable 101 being released and retrieved by the cable mechanism 100.

[0044] The cable mechanism 100 may further include a housing 130, and the motor assembly 110 and the pulley assembly 120 may be disposed within the housing 130. For example, the motor assembly 110 may be disposed in the upper part of the housing 130, and the pulley assembly 120 may vertically move within the housing 130 below the motor assembly 120. Alternatively, the motor assembly 110 may be disposed in the lower part of the housing 130, and the pulley assembly 120 may vertically move within the housing 130 above the motor assembly 110. In other embodiments, the motor assembly 110 may be disposed in the left or right part of the housing 130, and the pulley assembly 120 may horizontally move within the housing 130 relative to the motor assembly 110. Thus, the moving direction (e.g., vertical, horizontal, or at an angle) of the pulley assembly 120 may depend on the arrangement of the motor assembly 110 and the pulley assembly 120 within the housing 130. Additionally, corresponding to the movement of the pulley assembly 120 between the first position and the second position, the moving direction (i.e., release or retraction) of the cable 101 may depend on the arrangement of the motor assembly 110 and the pulley assembly 120 within the housing 130. For example, the first position and the second position may refer to the "raised" position or the "lowered" position of the pulley assembly 120 relative to the motor assembly 110. The specific reference to the "raised" position or the "lowered" position herein only refers to the exemplary arrangement of the motor assembly 110 and the pulley assembly 120 within the housing 130, and this is not limited herein.

[0045] The housing 130 may be at least partially sealed relative to the outside. For example, the housing 130 may only have one output opening 131 through which the cable 101 is released or retracted from the housing 130. The housing 130 can thus protect the motor assembly 110, the pulley assembly 120, and other components within the housing 130 from damage that may affect the operation of the cable mechanism 100. The housing 130 can also protect the user from contacting (or interfering with) the high-voltage / high-current power transmission lines connected to the cable mechanism 100. The housing 130 may also have an input opening 132 to receive input power for connection to the cable 101. The positions of the output opening 131 and the input opening 132 on the housing 130 may vary and are not limited herein. For example, as Figure 1 shown, the output opening 131 may be located in the upper part of the housing 130, and the input opening 132 may be located in the lower part of the housing 130.

[0046] The fixed end 105 of the cable 101 can be disposed within the housing 130, and the free end 102 of the cable 101 can be disposed outside the housing 130. In the first position, the maximum length of the cable 101 can be disposed within the housing 130. For example, the first position can define when the cable 101 is retracted, and when retracted, most of the cable 101 is received within the housing 130 for storage. In the second position, the minimum length of the cable 101 can be disposed within the housing 130. For example, the second position can define when the cable 101 is released, and when released, most of the cable 101 is located outside the housing for use. It should be understood that when the cable 101 is retracted, a portion of the cable 101 may remain outside the housing 130, and when the cable 101 is released, a portion of the cable 101 may remain within the housing 130. Depending on the requirements of the specific usage scenario, different lengths of the cable 101 can be released to be located outside the housing 130. The length of the cable 101 that can be released from the housing 130 may be limited by industry standards. For example, some standards may limit the length of the cable 101 that can be released from the housing 130 to not exceed 25 feet. Compared with other cable management systems, the cable mechanism 100 of the present disclosure can use more of the cable 101 because the minimum length of the cable 101 disposed within the housing 130 in the second position can be less than that of other cable management systems. In addition, compared with other cable management systems, more of the cable 101 can be managed within the housing 130 because the minimum length of the cable 101 disposed outside the housing 130 in the first position can be less than that of other cable management systems. This can prevent excess cable 101 from remaining outside the housing 130 when not in use.

[0047] The fixed end 105 of the cable 101 can be disposed at any position within the housing 130, depending on the system design. For example, the fixed end 105 of the cable 101 can be routed downward to the base of the housing 130 to connect to an Electric Vehicle Supply Equipment (EVSE) system 140. The EVSE system 140 can be disposed within the housing 130, or can be an external component connectable to the fixed end 105 of the cable 101 within the housing 130. The connection location of the fixed end 105 of the cable 101 to the EVSE system 140 can be adjusted and can be changed according to the input and output positions of the cable mechanism 100 in a specific application. The free end 102 of the cable 101 can be connected to a rechargeable device (such as an Electric Vehicle (EV)). Thus, the EVSE 140 can be used to charge the EV through the cable 101 and the cable mechanism 100.

[0048] Figure 2 Figures to 5 illustrate an example cable mechanism 100 according to an embodiment of the present disclosure. Refer to Figure 2, the pulley assembly 120 may include a linear motion guide 121, a sliding carriage 122 movable along the linear motion guide 121 between a first position and a second position, at least one movable pulley 123 disposed on the sliding carriage 122, and at least one fixed pulley 124 disposed adjacent to the motor assembly 110 above the sliding carriage 122. The linear motion guide 121 may include one or more guide rails, a pair of guide rails, or any other linear motion guiding mechanism known in the art. The sliding carriage 122 may be in a first position (such as Figure 3A shown) and a second position (such as Figure 3B shown), and move between them to change the vertical position of the movable pulley 123 when the cable 101 moves in the release direction or the retraction direction. As shown in Figure 4A , 4B , and 4C, the following portion 104 of the cable 101 may be wound around at least one movable pulley 123 and at least one fixed pulley 124 arranged in sequence. When the sliding carriage 122 is in the first position, the maximum distance may be between at least one movable pulley 123 and at least one fixed pulley 124. Therefore, the maximum length of the cable 101 wound around at least one movable pulley 123 and at least one fixed pulley 124 can be stored in the housing 130 for storage. When the sliding carriage 122 is in the second position, the minimum distance may be between at least one movable pulley 123 and at least one fixed pulley 124. Therefore, the cable 101 wound around at least one movable pulley 123 and at least one fixed pulley 124 is the minimum length of the cable 101, so that the remaining length of the cable 101 can be released from the housing 130.

[0049] It should be understood that, compared with a fixed pulley, the movement of the pulley assembly 120 can allow more cable 101 to be released and retracted from the cable mechanism 100. For example, a fixed pulley system always requires a fixed length of cable to wind around the pulley, which limits the length of the cable that can be released and stored. In contrast, the pulley assembly 120 of the present disclosure changes the length of the cable wound around at least one movable pulley 123 and at least one fixed pulley 124, thereby increasing the length of the cable that the cable mechanism 100 can release and store.

[0050] The sliding carriage 122 may be motorized or pneumatically controlled. For example, the pulley assembly 120 may further include a drive motor 125 for driving a drive chain 126. The drive chain 126 may be a chain, a drive belt (such as a timing belt, a synchronous belt, etc.), or a guide cable spool that can be driven by the drive motor 125. The sliding carriage 122 may be fixed to the drive chain 126, so that when the drive motor 125 drives the drive chain 126, the sliding carriage 122 moves along the linear motion guide 121 between the first position and the second position. Although Figure 2The exemplary cable mechanism 100 shown in FIGS. 1 to 5 includes two drive motors 125 for driving two drive chains 126, but the cable mechanism 100 can be operated by a single drive motor 125 and a single drive chain 126, and other structures for moving the sliding carriage 122 fall within the scope of the present disclosure. The drive motor 125 can also be used to move the sliding carriage 122 through other lifting mechanisms (such as a screw lifting mechanism), which is not limited herein.

[0051] The pulleys of the pulley assembly 120 can have a large enough diameter to minimize the stress on the cable 101 during movement. For example, the diameter of at least one movable pulley 123 and at least one fixed pulley 124 can be at least 5 times the diameter of the cable 101. The ratio of the pulley diameter to the cable diameter can be greater than 5:1. For example, this ratio can be 10:1, 12:1, or greater, and any ratio therebetween. If this ratio is less than 5:1, the cable 101 needs to bend more sharply around the pulley, which may cause stress on the cable 101 and affect the smooth operation of the cable mechanism 100. In some embodiments, the diameter of the cable 101 can be 10 to 80 millimeters. Correspondingly, the diameter of at least one movable pulley 123 and at least one fixed pulley 124 can be 100 to 960 millimeters or greater. When the stiffness of the cable 101 makes it difficult to wind into a loop with a diameter of at least 5 times the cable diameter without generating excessive tension, additional guide pulleys 127 can be used to ensure that the cable 101 is assembled within the envelope space provided by the pulley assembly. The guide pulley 127 can be set at a position 10 times or more the cable diameter away from the mounting axis of the movable pulley 123 or the fixed pulley 124. The guide pulley 127 can be alternately set at the pulley tangent point or on the cable bending arc to constrain the cable 101 to move along a predetermined path. The size of each pulley in the pulley assembly 120 can depend on the internal space of the housing 130. In some embodiments, at least one movable pulley 123 and at least one fixed pulley 124 have the same size. Alternatively, at least one movable pulley 123 and at least one fixed pulley 124 have different sizes. Therefore, the size and position of the pulley combination of the pulley assembly 120 can be changed to achieve the smooth operation of the cable mechanism 100.

[0052] The pulley assembly 120 may include additional pulleys to form additional cable turns and increase the available cable length. For example, at least one movable pulley 123 may include a plurality of movable pulleys 123, and at least one fixed pulley 124 may include a plurality of fixed pulleys 124. The following portion 104 of the cable 101 may alternately wrap around each of the plurality of movable pulleys 123 arranged in sequence and each of the plurality of fixed pulleys 124. The number of pulleys in the plurality of movable pulleys 123 may be n, and the number of pulleys in the plurality of fixed pulleys 124 may be m. In some embodiments, m = n. Alternatively, m = n ± 1. For example, the pulley assembly 120 may include 3 movable pulleys 123 and 2 fixed pulleys 124. A separator may be provided between each of the plurality of movable pulleys 123 and each of the plurality of fixed pulleys 124 to keep the following portion 104 of the cable 101 separated between the respective coils. The size of each of the plurality of movable pulleys 123 and each of the plurality of fixed pulleys 124 may be kept consistent between the respective coils. Alternatively, the size of each of the plurality of movable pulleys 123 and each of the plurality of fixed pulleys 124 may be different between the respective coils. In certain cases, changing the diameter between consecutive pulleys may keep the tension of the cable 101 more uniform compared to consistent sizes. Therefore, the combination and size of the pulleys of the pulley assembly 120 may be changed to achieve smooth operation of the cable mechanism 100.

[0053] Each movable pulley 123 and each fixed pulley 124 may not be parallel, such that the subsequent pulley on each turn of the cable 101 has an input at a position intersecting the plane where the previous pulley is located. For example, as Figure 6A shown, a set of pulleys A may be offset by an angle θ relative to another set of pulleys B. Therefore, when the cable wraps around consecutive pulleys, the angle of pulley B allows the cable to leave the first pulley A at an angle and enter the next pulley A in the coil. The angle θ may depend on the sizes of pulleys A and B and the spacing between each of pulleys A and B. In some embodiments, the angle θ may be 5° to 15°. In some arrangements, one of the sets of pulleys A or B may be aligned with the orthogonal direction, and the other set may be offset by an angle θ relative to the orthogonal direction. For example, as Figure 6B shown, the cable wrapping around a set of pulleys A is aligned with the orthogonal direction, while the cable wrapping around a set of pulleys B is offset by an angle θ relative to the orthogonal direction. Alternatively, both sets of pulleys A and B may be offset relative to the orthogonal direction such that the two sets of pulleys are offset by an angle θ relative to each other. For example, as Figure 6C shown, the cables wrapping around both sets of pulleys A and B are offset by an angle of θ / 2 relative to the orthogonal direction, forming an offset of angle θ. It should be understood that the offsets of the two sets of pulleys A and B relative to the orthogonal direction may be equal or different.

[0054] The plurality of movable pulleys 123 or the plurality of fixed pulleys 124 may be offset relative to the other. For example, Figure 7In the illustrated embodiment, multiple fixed pulleys 124 may be offset at an angle θ relative to multiple movable pulleys 123. Alternatively, multiple movable pulleys 123 may be offset at an angle θ relative to multiple fixed pulleys 124. Compared with parallel pulleys, the non-parallel arrangement of consecutive pulleys may enable the cable mechanism 100 to operate more smoothly. For parallel pulleys, if the cable 101 has a large thickness or stiffness, or both, excessive friction may occur between the cable 101 and the pulleys. A cable 101 composed of copper or aluminum wire with a diameter greater than 6 mm, or particularly a multi-core cable with a diameter greater than 10 mm, may have problems when releasing 80% or more of the cable length because the angle at which the cable 101 must bend between consecutive layers of pulleys will exert excessive force on the pulley edges, or may cause lateral forces that can dislodge the cable from the rollers if ordinary rollers are used. The minimum θ angle between consecutive pulleys may be determined by the cable diameter. For example, for a five-core cable with a diameter of 16.4 mm, the minimum angle may be 6 to 8°.

[0055] In some embodiments, each pulley of the pulley assembly 120 may include a series of pulleys arranged in an arc. For example, at least one movable pulley 123 may include a series of pulleys arranged in an arc (as Figure 4C shown), and at least one fixed pulley 124 may include a series of pulleys arranged in an arc (as Figure 4B shown). The arc may refer to a circular arc, a non-circular arc, or any other arrangement in a conical section, which is not limited herein. In a multi-layer structure, an arc-shaped pulley group has advantages over independent pulleys in that it maximizes the utilization of the cable carried in the system by eliminating the limitation that the pulley must move to a perfect tangent position. For example, for a series of pulleys arranged in an arc, the distance between the two center points of the ideal pulley axis is only equal to the sum of the two largest radii of the end pulleys in the top and bottom arrays, while for two independent pulleys, this distance is significantly increased to the sum of the radii of the two independent pulleys (in some embodiments, this distance is at least 5 times the cable diameter). For example, the pulley arc radius of a 10 mm cable system may be 50 mm. For this cable diameter, the minimum distance between the two pulleys will reach 100 mm or more. In the same case, if a series of small pulleys are used to form a pulley arc radius of 50 mm, the radius of a single pulley may be 10 mm, such that the minimum distance between the two pulley arcs can be close to 20 mm. Since the available cable length is related to the number of cable turns, a series of arc-shaped pulleys can minimize the length of the cable 101 that must be retained within the housing 130, thereby increasing the length of the usable cable 101 released from the housing 130.

[0056] The axis of each pulley in the series of pulleys can be arranged so that the bearing surface of each pulley is perpendicular to the motion path of the cable 101. For example, the angle between the consecutive pulleys A1 and A2 can be an angle φ. The angle φ can be determined by the diameter of the cable 101 and the size and arrangement of the pulleys. For example, Figure 8A As shown, the angle between the continuous pulleys A1 and A2 can be φ = 0°. Alternatively, Figure 8B As shown, the angle between consecutive pulleys A1' and A2' may be φ>0°. Each series of at least one movable pulley 123 and at least one fixed pulley 124 may be arranged so that the angle φ remains constant or varies between consecutive pulleys in each series or between each coil.

[0057] Each of the plurality of movable pulleys 123 can move independently or in conjunction with other pulleys. In other words, the sliding bracket 122 can be used to move all of the plurality of movable pulleys 123 as a whole, or to move the plurality of movable pulleys 123 separately or sequentially. Figures 4A to 4C In the illustrated example cable mechanism 100, each of the plurality of movable pulleys 123 may be disposed on a sliding bracket 122, so that the sliding bracket 122 simultaneously drives the plurality of movable pulleys 123 to move between the second position and the first position. Alternatively, each of the plurality of movable pulleys 123 may be disposed on its independent sliding bracket (or an independent movable component of the sliding bracket 122), so that each sliding bracket may sequentially drive each of the plurality of movable pulleys 123 to move between the second position and the first position. For example, initially, the three movable pulleys 123 are in the first position, and the sliding bracket 122 may first move the first movable pulley to the second position, then the second, and finally the third (after the previous pulley moves to the second position or a position between the first and second positions). In the same example, when moving back to the first position, the sliding bracket 122 may move the three movable pulleys 123 in reverse order (3, 2, 1). Each sliding bracket 122 can also be used to simultaneously move each of the plurality of movable pulleys 123 to achieve quick release or retraction.

[0058] See also Figure 5A and 5B, the motor assembly 110 may include an outlet motor 111 for driving a pair of drive rollers 112. The guiding portion 103 of the cable 101 may be disposed between the drive rollers 112 such that when the outlet motor 111 drives the pair of drive rollers 112, the free end 102 of the cable 101 is released or retracted. For example, the spacing of the drive rollers 112 may be designed such that the guiding portion 103 of the cable 101 is clamped between the drive rollers 112, so that the rotation of the drive rollers 112 can determine the release or retraction of the cable 101 according to the steering. Through the combined action of the force applied by the drive rollers 112 and the fixed end 105 of the cable 101, the cable 101 always maintains tension on the pulley assembly 120. The force applied by the drive rollers 112 can also provide power for the cable 101 when it is released or retracted. The motor assembly 110 may further include at least one pair of guide rollers 113 disposed upstream and / or downstream of the pair of drive rollers 112. The at least one pair of guide rollers 113 can be used to change the angular direction in which the cable 101 is released or retracted. For example, the pair of guide rollers 113 can guide the cable 101 out of the output opening 131 of the housing 130 for use.

[0059] As Figure 1As shown, the cable mechanism 100 may further include a controller 150 electrically connected to the motor assembly 110 and the pulley assembly 120. For example, the controller 150 can be used to synchronize the operation of the drive motor 125 of the pulley assembly 120 with the outlet motor 111 of the motor assembly 110. By synchronizing the rotation of the drive motor 125 and the outlet motor 111, the cable 101 maintains tension when being released and retracted. If the tension is lost, the cable 101 may bend during release, resulting in jamming or entanglement of the cable mechanism 100. If the tension of the cable 101 is too high, a greater driving force is required to drive the cable 101. Therefore, the controller 150 can be used to adjust the tension of the cable 101 by controlling the speeds of the drive motor 125 and the outlet motor 111. For example, when the cable 101 is released from the cable mechanism 100, the controller 150 can control the speed of the drive motor 125 to be 5% to 15% slower than the speed of the outlet motor 111. When the cable 101 is retracted into the cable mechanism 100, the controller 150 can control the speed of the drive motor 125 to be 15% to 30% slower than the speed of the outlet motor 111. Alternatively, the controller 150 can control the speed ratio of the outlet motor 111 to the drive motor 125 to be approximately 5.5:1 to 6:1. Thus, the synchronous rotation of the drive motor 125 and the outlet motor 111 can achieve smooth operation of the cable mechanism during release and retraction. It should be understood that the speeds of the drive motor 125 and the outlet motor 111 depend on the release and retraction speeds of the cable 101 required for a specific application, which are not limited herein. The relative speeds of the drive motor 125 and the outlet motor 111 can remain constant or vary with the movement of the pulley assembly 120 between the first position and the second position. The relative speeds of the drive motor 125 and the outlet motor 111 also depend respectively on the transmission ratios and transmission devices of the pulley assembly 120 and the motor assembly 110, and these factors can also be designed to provide a tension effect. The number of cable turns of the cable 101 also affects the relative speed. For example, more turns result in a higher speed ratio, while fewer turns result in a lower ratio. For a single-turn cable, the ratio tends to be 1:1.

[0060] A control switch 155 can be provided to control the operation of the cable mechanism 100. The control switch 155 can be provided at the free end 102 of the cable 101 and electrically connected to the controller 150. For example, the control switch 155 can communicate with the controller 150 wirelessly, or the control switch 155 can be wired to the controller 150 through the cable 101. The control switch 155 can be used to send instructions to the controller 150 to release or retract the cable 101. For example, the control switch 155 can instruct the controller 150 to control the outlet motor 111 and the drive motor 125 to operate in the corresponding directions to release or retract the cable 101. In some embodiments, the control switch 155 can be used to send instructions to the controller 150 to release or retract a specific length of the cable 101, and the specific length of the cable 101 is less than or equal to the maximum length of the cable 101 that can be released from the housing 130. The specific length of the cable 101 can be a preset length or a user-defined length of one or more cables 101. The control switch 155 can be operated by a single button, two buttons (one button corresponding to one direction of the cable 101), or by an additional button to set the specific release length of the cable 101. Alternatively, the control switch 150 can be operated by pulling the free end 102 of the cable 101.

[0061] With the cable mechanism 100 of the present disclosure, the cable 101 can be self-separated through the pulley assembly 120. For example, since the following part 104 of the cable 101 is wound around the movable pulley 123 and the fixed pulley 124, the pulley assembly 120 can prevent different sections of the cable 101 from overlapping with each other. In the first position, the movable pulley 123 can maintain a distance from the fixed pulley 124, and even in the second position, the sections of the cable 101 in adjacent pulley layers can be in non-contact. This can significantly reduce the heat generation of any individual part of the cable 101, so that the cable can still maintain its full current-carrying capacity even when in the retracted position. If the rollers and the roller support structure are made of a slightly heat-conductive material, its heat dissipation effect will be significantly better than that of a standard coiled cable. The cable mechanism 100 can provide a simple and controllable cable retracting and releasing solution, which is suitable for high-current EV charging applications.

[0062] Another embodiment of the present disclosure provides a method 200 for releasing or retracting a cable. As Figure 9A shown, the method 200 can include the following steps.

[0063] Step 210: Provide a cable mechanism. The cable mechanism can be the aforementioned cable mechanism 100, and its details will not be elaborated here.

[0064] Step 220: Move the pulley assembly from the first position to the second position to release the cable. By moving to the second position, a certain length of the cable can be released from the cable mechanism, thereby providing an additional length of the available cable.

[0065] Step 230: Move the pulley assembly from the second position to the first position to retract the cable. By moving to the first position, a certain length of the cable can be retracted into the cable mechanism, thus achieving efficient cable storage.

[0066] It should be understood that steps 220 and 230 can be repeated any number of times to simply and efficiently release or retract the cable through the cable mechanism of the present disclosure. The second position and the first position mentioned in steps 220 and 230 can refer to any relative positions and movements of the pulley assembly. In some embodiments, the second position and the first position can refer to the positions at the maximum movement range of the pulley assembly or any positions within the movement range. For example, the second position can correspond to the position where the pulley assembly releases the maximum cable length, and the first position can correspond to the position where the pulley assembly releases the minimum cable length. Alternatively, the second position and the first position can correspond to the positions where the pulley assembly releases other cable lengths, and the specific cable release lengths at these two positions are not limited herein.

[0067] In some embodiments, the cable mechanism can include a drive motor for moving the pulley assembly between the first position and the second position, an outlet motor in the motor assembly for releasing or retracting the free end of the cable, and a controller that is electronically communicable with the drive motor and the outlet motor. Thus, as Figure 9B shown, steps 220 and 230 of method 200 can be replaced with the following steps.

[0068] Step 225: Synchronously control the drive motor and the outlet motor to move the pulley assembly from the first position to the second position to release the free end of the cable, so that the cable maintains tension when being released. For example, when the cable is released from the cable mechanism, the controller can control the speed of the drive motor to be 5% to 15% slower than the speed of the outlet motor.

[0069] Step 235: Synchronously control the drive motor and the outlet motor to move the pulley assembly from the second position to the first position to retract the free end of the cable, so that the cable maintains tension when being retracted. For example, when the cable is retracted into the cable mechanism, the controller can control the speed of the drive motor to be 15% to 30% slower than the speed of the outlet motor.

[0070] Through method 200 of the present disclosure, the cable mechanism can retract and release the cable in a simple and controllable manner. This process is highly repeatable and user-friendly, and is suitable for public EV charging applications.

[0071] Although the present disclosure has been described with reference to one or more specific embodiments, it should be understood that other embodiments can be designed without departing from the scope of the present disclosure. Therefore, the scope of the present disclosure is only defined by the appended claims and their reasonable interpretations.

Claims

1. A cable mechanism for releasing and retracting a cable having a free end and a fixed end, the cable mechanism comprising: A motor assembly for engaging a guiding portion of the cable to release or retract the cable; And A pulley assembly for engaging a following portion of the cable, the following portion being disposed between the guiding portion and the fixed end of the cable, wherein the pulley assembly is movable relative to the motor assembly between a first position and a second position; Wherein moving the pulley assembly from the first position to the second position releases the cable, and moving the pulley assembly from the second position to the first position retracts the cable.

2. The cable mechanism according to claim 1 further includes a housing, wherein, The motor assembly is disposed within the housing, and the pulley assembly is vertically movable relative to the motor assembly within the housing.

3. The cable mechanism according to claim 2, wherein, The housing is at least partially sealed, the fixed end of the cable is disposed within the housing, and the free end of the cable is disposed outside the housing.

4. The cable mechanism according to claim 2, wherein, In the first position, the maximum length of the cable is disposed within the housing, and in the second position, the minimum length of the cable is disposed within the housing.

5. The cable mechanism according to claim 1, wherein, The pulley assembly includes: A linear motion guide rail; A sliding carriage movable along the linear motion guide rail between the first position and the second position; At least one movable pulley disposed on the sliding carriage; and At least one fixed pulley disposed adjacent to the motor assembly; Wherein the following portion of the cable is wound around the at least one movable pulley and the at least one fixed pulley arranged in sequence.

6. The cable mechanism according to claim 5, wherein, The pulley assembly further includes a drive motor for driving a drive chain, wherein the sliding carriage is fixed to the drive chain such that when the drive motor drives the drive chain, the sliding carriage moves along the linear motion guide rail between the first position and the second position.

7. The cable mechanism according to claim 5, wherein, The diameter of the at least one movable pulley and the at least one fixed pulley is at least 5 times the diameter of the cable.

8. The cable mechanism according to claim 5, wherein, The at least one movable pulley and the at least one fixed pulley are not parallel, such that the subsequent pulley on each turn of the cable has an input at a position intersecting the plane of the preceding pulley arranged in sequence.

9. The cable mechanism according to claim 5, wherein, The at least one movable pulley and the at least one fixed pulley each include a series of pulleys arranged in an arc, and the radius of the arc is at least 5 times the radius of the cable.

10. The cable mechanism according to claim 5, wherein, The at least one movable pulley includes a plurality of movable pulleys, the at least one fixed pulley includes a plurality of fixed pulleys, and the following portion of the cable is alternately wound around one of the plurality of movable pulleys and one of the plurality of fixed pulleys arranged in sequence.

11. The cable mechanism according to claim 1, wherein, The motor assembly includes an outlet motor for driving a pair of drive rollers, wherein the guiding portion of the cable is disposed between the pair of drive rollers such that when the outlet motor drives the pair of drive rollers, the pair of drive rollers engage the guiding portion of the cable to release or retract the free end of the cable.

12. The cable mechanism according to claim 11, wherein, The motor assembly further includes at least one pair of guide rollers arranged upstream and / or downstream of the pair of drive rollers, wherein the at least one pair of guide rollers is configured to change the angular direction in which the cable is released or retracted.

13. The cable mechanism according to claim 1, further comprising: a drive motor configured to move the pulley assembly between the first position and the second position; an outlet motor in the motor assembly configured to release or retract the free end of the cable; and a controller configured to synchronize the drive motor and the outlet motor such that, during release or retraction, the cable maintains tension between the guiding portion and the fixed end.

14. The cable mechanism according to claim 13, wherein, The controller is configured to control the speed of the drive motor to be slower than the speed of the outlet motor when the cable is released from the cable mechanism.

15. The cable mechanism according to claim 13, wherein, The controller is configured to control the speed of the drive motor to be slower than the speed of the outlet motor when the cable is retracted into the cable mechanism.

16. The cable mechanism according to claim 13, further comprising a control switch provided at the free end of the cable, wherein the control switch is in electronic communication with the controller.

17. The cable mechanism according to claim 16, wherein, The control switch is configured to send an instruction to the controller to release or retract the cable.

18. The cable mechanism according to claim 17, wherein, The control switch is configured to send an instruction to the controller to release or retract a specific length of the cable.

19. A method of releasing or retracting a cable having a free end and a fixed end, the method comprising: providing a cable mechanism comprising: a motor assembly configured to engage a guiding portion of the cable to release or retract the cable; and a pulley assembly configured to engage a following portion of the cable, the following portion being arranged between the guiding portion and the fixed end of the cable, wherein the pulley assembly is movable relative to the motor assembly between a first position and a second position; and moving the pulley assembly from the first position to the second position to release the cable, or moving the pulley assembly from the second position to the first position to retract the cable.

20. The method according to claim 19, wherein, Moving the pulley assembly from the first position to the second position, or moving the pulley assembly from the second position to the first position, comprises: synchronously controlling a drive motor and an outlet motor of the motor assembly to move the pulley assembly between the first position and the second position and to release or retract the free end of the cable such that the cable maintains tension during release or retraction.

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