Charging Arm Conductor Carrier for Heavy EV Fast-Charge Cables
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Charging cables for electric vehicles requiring high power transmission are excessively heavy and cumbersome due to large conductor cross-sections, making them difficult for average users to handle effectively.
Innovation Solution
A charging arm system comprising rigid arms with conductor sections and a charging connector assembly, designed to support and manage high-power charging cables, allowing for lightweight and flexible conductor options, including thicker stranded cables or flexible busbars, with integrated support structures to reduce user handling burden.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If charging cables are designed with large conductor cross-sections to transmit high power, then power transmission capability is improved, but cable weight and handling difficulty increase
Solution Approach 1:
The charging system divides the power transmission path into multiple rigid arm segments (first rigid arm, second rigid arm, third rigid arm) instead of using a single heavy cable. Each segment contains conductor sections that transmit power collectively, distributing the weight and improving handling while maintaining high power transmission capability.
Solution Approach 2:
Rigid arms serve as intermediary structures between the power supply and the charging connector. These rigid arms provide mechanical support and structural integrity, allowing the use of lighter conductor sections within them while maintaining the ability to transmit high power through the distributed conductor system.
2Power
If charging cables use large conductor cross-sections for high power, then power transmission is improved, but ease of operation deteriorates
Solution Approach 1:
The charging system segments the power transmission function across multiple rigid arms with conductor sections, creating a manageable structure that users can operate easily. The modular design allows the charging arm to be positioned and connected without requiring users to handle heavy, cumbersome cables.
Solution Approach 2:
The patent replaces the traditional flexible cable mechanical system with a rigid arm structure that incorporates conductor sections. This substitution provides structural support and positioning capabilities, eliminating the need for users to manually handle and position heavy cables, thereby improving ease of operation.
3Ease of operation
If rigid arms with conductor sections are used instead of heavy cables, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The rigid arms in the charging system serve multiple functions simultaneously: they provide mechanical support, structural integrity, positioning capability, and power transmission through integrated conductor sections. This multi-functionality reduces the need for separate components, thereby managing device complexity while improving ease of operation.
Solution Approach 2:
The patent merges the structural support function and power transmission function into a single integrated rigid arm structure. The conductor sections are incorporated within the rigid arms, combining what would traditionally be separate elements (cables and support structures) into a unified system that simplifies the overall device architecture.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A charging arm system for an electric vehicle charging station is provided. The charging system includes a first rigid arm having a first proximal end and a first distal end, the first proximal end configured for connecting to a power supply, a first support point rotatably supporting the first proximal end, a second rigid arm having a second proximal end and a second distal end, the second proximal end being rotatably coupled to the first distal end, a charging connector assembly coupled to the second distal end and configured for connecting to a charging inlet of an electric vehicle, and a vertical support coupled to the second rigid arm or the charging connector assembly for supporting the second rigid arm or the charging connector assembly. The first rigid arm comprises a first conductor section and the second rigid arm comprises a second conductor section, and the first conductor section and the second conductor section are electrically connected for providing electric power from the power supply to the electric vehicle.