EV Charger Cable Arm Rail for Curvature and Abrasion Control
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Solution Overview
Problem
Charging cables for electric vehicles often suffer from friction and abrasion due to repeated use, leading to damage and contamination from the floor, and existing solutions do not effectively maintain the optimal curvature of the cable during charging.
Innovation Solution
A charger design featuring an arm body with a guide rail and pulley system that guides the charging cable, incorporating a gas spring damper to manage cable tension and curvature, minimizing friction and abrasion by allowing the cable to be drawn in and out without a motor, and maintaining a curvature within a specific range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a motor-driven cable management system is used, then cable alignment and control precision are improved, but device complexity and cost increase
Solution Approach 1:
The cable management system uses the cable's own weight and the elastic force of the coiled spring to automatically align and retract the cable without requiring external motor-driven actuation. The cable naturally feeds through the guide rail and aligns itself during charging operations.
Solution Approach 2:
The patent removes the motor and complex control mechanisms from the cable management system, extracting only the essential passive components (guide rail, coiled spring, cable) needed to achieve cable alignment and retraction through natural physical forces.
2Ease of operation
If the charging cable is repeatedly pulled out and retracted, then charging convenience is improved, but friction and abrasion increase leading to cable damage
Solution Approach 1:
The cable is stored in a coiled spring configuration rather than a straight or folded state. This curved, spiral arrangement distributes mechanical stress evenly during retraction and minimizes friction points, reducing abrasion while maintaining ease of cable deployment.
Solution Approach 2:
The guide rail acts as an intermediary component that guides the cable smoothly during retraction, preventing direct contact between the cable and rough surfaces. This intermediate structure reduces friction and protects the cable from abrasion during repeated use.
3Length of moving object
If the cable is allowed to touch the floor during use, then cable length flexibility is improved, but contamination and damage from floor contact increase
Solution Approach 1:
Instead of allowing the cable to extend horizontally across the floor surface, the system guides the cable to retract vertically along the guide rail into the charger body. This dimensional change elevates the cable path from the contaminated floor level to a clean, protected vertical path.
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 solution reduces friction and abrasion, extends the lifespan of the charging cable, and allows for smooth, efficient charging without the need for a motor-driven cable management system, enhancing user experience and cable durability.
Implementation Method 1
incorporating a gas spring damper to manage cable tension and curvature
Implementation Method 2
A charger design featuring an arm body with a guide rail and pulley system that guides the charging cable
Data Source
AI summary
A charger comprises a main body to which a charging cable is connected; an arm body disposed on the main body and having an arm space; an arm guide accommodated in the arm space and guiding the charging cable; and an arm rail formed on the arm body and having an outlet through which the charging cable passes, wherein a portion of the charging cable accommodated in the arm space is disposed to have at least one curvature.