EV Charger Cable Tension Sensing With a Transfer Lever
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Solution Overview
Problem
Electric vehicle charging stations face challenges with cable management, particularly with high-voltage chargers, where large cables can be difficult to use and pose accessibility issues, and are prone to damage and safety hazards when left on the ground.
Innovation Solution
A cable management system that includes a mechanical wire coupled to the charging cable, a force transmission coupler, and a controller to retract and extend the cable, keeping it off the ground and preventing damage, while also being accessible for users with disabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high-voltage charging capabilities are increased, then charging power is improved, but cable size and weight increase making it difficult to use
Solution Approach 1:
The patent implements a dynamic cable management system with motorized winches that automatically retract and extend cables based on charging state and user interaction. The cable transitions from extended during charging to retracted when not in use, adapting its position dynamically to maintain usability despite increased cable thickness from high-voltage requirements.
Solution Approach 2:
The system incorporates sensors that detect cable extension state, user pulling force, and charging completion to automatically control cable retraction without manual intervention. The cable management system serves itself by detecting when the cable needs to be retracted and executing the retraction autonomously, reducing the burden on users despite the cable's increased size.
2Ease of operation
If cable is left extended on the ground, then accessibility is maintained, but cable damage and safety hazards increase
Solution Approach 1:
The system proactively retracts the cable automatically upon detecting charging completion or potential hazards, preventing damage before it occurs. The cable is pulled back into the housing in advance of any potential harm, eliminating tripping hazards and exposure to environmental damage while maintaining accessibility during active use.
Solution Approach 2:
Sensors continuously monitor cable position, extension state, and external forces to provide feedback to the control system. This feedback loop enables the system to detect when the cable is fully extended and needs retraction, or when external forces indicate potential damage risks, allowing real-time adjustments to maintain both accessibility and safety.
3Reliability
If cable management system is added, then cable protection is improved, but device complexity increases
Solution Approach 1:
The cable management system performs multiple functions: it supports high-voltage power transmission, provides automated retraction, detects user interaction through force sensing, prevents cable damage, and eliminates safety hazards. By consolidating these diverse functions into a single integrated system with shared components like the winch mechanism and sensor array, the patent reduces overall complexity compared to having separate systems for each function.
Solution Approach 2:
The patent combines the cable support structure, motorized retraction mechanism, force sensing elements, and control system into an integrated housing unit. The transfer lever mechanism merges force transmission from multiple sensors into a single control signal for the winch system, consolidating multiple protective and operational functions into one unified device that manages the cable comprehensively.
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 system enhances accessibility, prevents cable damage, and ensures safety by keeping the charging cable organized and protected from environmental hazards, making high-voltage charging more efficient and user-friendly.
Implementation Method 1
A force transmission coupler may be connected to the transfer lever at a portion of the transfer lever that is in spaced relation to the pivot point. The force transmission coupler may receive the mechanical wire and transmit at least a portion of a force applied to the mechanical wire to the transfer lever to cause the transfer lever to pivot
Implementation Method 2
A sensor may be mounted within the enclosure and aligned with a portion of the transfer lever that is in spaced relation to the pivot point. The sensor may be mounted to allow the sensor to be activated to a greater extend when the transfer lever is in a second orientation than in a first orientation
Data Source
AI summary
A cable management system for an electric vehicle charger includes a transfer lever pivotably mounted at a pivot point. A sensor may be mounted to be aligned with a portion of the transfer lever. A mechanical wire may be coupled to a charging cable associated with the electric vehicle charger. The cable management system may include a force transmission coupler connected to the transfer lever. The force transmission coupler may receive the mechanical wire and transmit a force applied to the mechanical wire to the transfer lever to cause the transfer lever to pivot from the first orientation to the second orientation to apply a greater pressure to the sensor. A wire retractor retracts and extends the mechanical wire based on sensor data.