EV Charging Cable Rotating Arm to Prevent Ground Drag
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Solution Overview
Problem
Existing electric vehicle (EV) charging systems face issues with cable degradation, frequent mechanical damage, thermal degradation, and safety hazards such as tripping hazards and user injuries from dropped connectors, despite compliance with safety directives being difficult to achieve practically.
Innovation Solution
A cable management system with a rotating arm mechanism that includes a fixed and extending body, allowing safe deployment and storage of EV charging cables, with features to prevent cable contact with the ground and user injury, and incorporating mechanical components for automated safety and convenience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a long cable is used to reach between EVSE and vehicle inlet, then the charging range is improved, but the cable becomes more susceptible to mechanical damage, abrasion, and tripping hazards
Solution Approach 1:
The patent implements a dynamic cable management system with a rotating arm and telescoping cable guide that automatically adjusts cable deployment based on vehicle position. The cable transitions from a static, ground-prone configuration to a dynamically controlled path that elevates and redirects the cable away from tripping hazards and mechanical damage sources while maintaining adequate charging range.
Solution Approach 2:
The patent introduces vertical and angular dimensions to cable management by mounting the cable guide on a rotating arm that extends from a vertical support. This three-dimensional cable routing system elevates the cable above ground level and redirects it through space, transforming the cable's path from a horizontal ground-level exposure to a controlled spatial configuration that reduces mechanical damage and tripping hazards.
2Productivity
If frequent deployment and storage cycles are performed, then charging convenience is improved, but cable degradation and mechanical damage accelerate
Solution Approach 1:
The patent incorporates protective features including cable guides with smooth transitions, abrasion-resistant routing paths, and controlled deployment mechanisms that prevent sharp bends and excessive tension. These protective measures are built into the system architecture to cushion the cable against mechanical stress during frequent deployment and storage cycles, extending cable lifespan while maintaining charging convenience.
Solution Approach 2:
The patent introduces intermediate components including a rotating arm mechanism, telescoping cable guide, and vertical support structure that act as mediators between the fixed EVSE and the moving vehicle. These intermediaries control cable movement, distribute mechanical stress, and prevent direct contact between the cable and ground or obstacles, reducing wear during frequent charging operations.
3Ease of operation
If cable is routed close to ground for easy access, then user convenience is improved, but tripping hazards and connector drop injuries increase
Solution Approach 1:
The patent elevates the cable from ground level to a suspended configuration using a rotating arm mounted on a vertical support. The cable is routed through a telescoping guide that maintains it above ground, transforming the accessibility model from horizontal ground-level access to vertical suspension with controlled deployment, eliminating tripping hazards while preserving user convenience.
Solution Approach 2:
The patent implements a feedback mechanism where the rotating arm and telescoping cable guide respond to vehicle approach and positioning. The system automatically adjusts cable deployment length and angle based on detected vehicle position, providing convenient access without requiring the cable to remain exposed on the ground, thereby eliminating tripping hazards while maintaining ease of operation.
4Device complexity
If a simple cable routing system is used, then device complexity is reduced, but safety control and cable protection capabilities are insufficient
Solution Approach 1:
The patent segments the cable management function into distinct components: a vertical support structure, a rotating arm mechanism, a telescoping cable guide, and a fixed EVSE connection point. This segmentation allows each component to perform a specific safety function (structural support, angular adjustment, cable path control, fixed anchoring) while maintaining overall system simplicity and reliability through modular, well-defined interfaces.
Solution Approach 2:
The patent introduces dynamic elements (rotating arm, telescoping guide) that provide active safety control and cable protection. These dynamic components automatically adjust cable positioning and tension based on operational conditions, enhancing safety protection capabilities without requiring complex electronic control systems, thereby maintaining relative simplicity while improving reliability.
Data Source
AI summary
A cable management system for the storage, deployment and support of an EV charging cable. The system is mounted at or near the source of power. The cable is electrically coupled to the power source and may be deployed and plugged into a port on the EV. The support system is mounted to a vertical support, and freely rotatably horizontal therefrom. The deployment end of the support system near the connector end of the holds the free end of the cable above the ground and includes a fixed length of free end of cord out of the body. The system may be expanded or contracted, in telescopic fashion, maintaining the free end of cord and charging head above the ground.