EV Charging Cable Tension Control for Variable Vehicle Load Profiles
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Solution Overview
Problem
Existing vehicle charging systems face challenges in efficiently managing cable tension due to varying vehicle sizes, orientations, and charge port locations, leading to increased pull force and reduced cable longevity.
Innovation Solution
A system that detects vehicle characteristics and adjusts cable tension using a load profile that maps tension to angle and length, allowing for optimized cable dispensing and retraction based on detected vehicle characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed cable tension is applied to all vehicles, then the cable dispensing system is simple to operate, but the cable longevity is reduced due to excessive pull force on certain vehicle types
Solution Approach 1:
The cable dispensing system dynamically adjusts cable tension based on detected vehicle characteristics (size, orientation, charge port location). The system transitions from a static fixed-tension approach to a dynamic adaptive approach where the tension force varies according to the specific vehicle being charged, thereby extending cable longevity without excessive complexity
Solution Approach 2:
The system changes the tension parameter of the cable based on detected vehicle characteristics. By measuring vehicle properties and adjusting the cable tension parameter accordingly, the system optimizes cable force for different vehicle types, preventing excessive pull force that would reduce cable longevity while maintaining operational simplicity through automated detection and adjustment
2Adaptability or versatility
If the cable length is increased to reach all charge port locations, then all vehicles can be charged, but the pull force on the cable increases significantly
Solution Approach 1:
The system adjusts the cable tension parameter based on the detected charge port location and vehicle characteristics. When the charge port is located far from the vehicle's rear (requiring longer cable extension), the system automatically reduces the dispensing force to compensate for the increased leverage and reduced cable longevity, thereby maintaining versatility across all vehicle types without excessive pull force
Solution Approach 2:
The system uses feedback from vehicle detection (charge port location, vehicle size, orientation) to automatically adjust cable dispensing parameters. This closed-loop approach allows the system to optimize both cable length and tension force based on real-time vehicle characteristics, achieving universal compatibility while preventing excessive force that would harm cable longevity
3Productivity
If high cable tension is applied to ensure rapid cable dispensing, then charging speed is improved, but manual labor increases and user experience deteriorates
Solution Approach 1:
The system dynamically changes the cable tension parameter based on vehicle characteristics and charge port location. For vehicles with charge ports close to the rear (shorter cable extension needed), the system applies higher tension for rapid dispensing. For vehicles requiring longer cable extension, the system automatically reduces tension, thereby maintaining high productivity where possible while improving ease of operation when needed
Data Source
AI summary
Cable tensioning based on load profiles is provided. A system can include a dispenser of a charger and one or more processors. The system can detect a characteristic of a vehicle. The system can determine, based at least in part on the characteristic of the vehicle, an amount of force to apply to a cable. The system can provide an instruction to cause the dispenser to apply the amount of force to the cable.