U-Shaped EV Charging Cable Guide for Dry, Accessible Plug Storage
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Solution Overview
Problem
Charging cables for electric vehicles are prone to being run over by vehicles, exposing contacts to moisture, and the charging plug is difficult to access, handle, and return to its original position safely and space-efficiently.
Innovation Solution
A cable guide system with a U-shaped charging cable configuration, featuring a deflection unit and cable carriers, allows the charging plug to be hung below a vertical deflection station, using a linear drive system for automatic movement and a spring mechanism for easy retrieval, ensuring minimal space usage and collision avoidance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the charging cable is laid out straight, then the charging plug is easily accessible, but the cable is prone to being run over by vehicles and exposed to moisture
Solution Approach 1:
The charging cable is arranged in a U-shape configuration with two legs running parallel to guide rails, transitioning from a straight horizontal layout to a three-dimensional suspended structure. This dimensional change allows the cable to be elevated above the ground, protecting it from vehicle damage and moisture while maintaining plug accessibility through vertical deflection.
Solution Approach 2:
A deflection unit with movable rollers is introduced that can dynamically adjust the position of the charging plug along the cable's length. This dynamic element allows the plug to be moved vertically to access the vehicle charging port while the U-shaped cable configuration remains stationary and protected above ground level.
2Object-affected harmful factors
If the charging plug is hung below a vertical deflection station, then vehicle movement is unrestricted and moisture protection is improved, but the plug becomes difficult to handle and return to original position
Solution Approach 1:
The deflection unit incorporates movable rollers that can be actively shifted along the cable to dynamically reposition the charging plug. This dynamic mechanism transforms the static hanging arrangement into an actively controllable system, enabling easy handling and automatic return of the plug to its original position through motorized or spring-assisted movement.
Solution Approach 2:
A spring mechanism is integrated into the deflection unit to provide automatic return force. When the charging plug is released after use, the spring automatically propels the deflection unit to return the plug to its original suspended position, eliminating the need for manual retrieval effort and ensuring consistent positioning.
3Volume of moving object
If a U-shaped cable configuration is used, then space efficiency is improved, but the cable requires active movement mechanisms to function properly
Solution Approach 1:
The cable guide system is segmented into distinct functional components: stationary guide rails providing structural support, movable rollers enabling cable deflection, and a spring mechanism for automatic return. This segmentation allows each component to perform its specific function with simple mechanics, reducing overall system complexity while maintaining the space-efficient U-shaped configuration.
Solution Approach 2:
The spring mechanism provides self-service by automatically returning the deflection unit to its initial position after use. This passive mechanical system eliminates the need for complex active control systems, motors, or sensors, achieving automatic plug repositioning through simple elastic energy storage and release while maintaining minimal space requirements.
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 provides easy access to the charging plug, protects it from moisture, and ensures safe, space-efficient storage, allowing unrestricted vehicle movement and easy handling of the charging cable.
Implementation Method 1
a spring mechanism for easy retrieval
Data Source
AI summary
The invention relates to a cable guiding system 1 for charging an electric vehicle, comprising a charging cable 2 with a charging plug 3 at one end, wherein the charging cable 2 is guided in a U-shape in its course from a connection end to its end with the charging plug 3 in a guiding device 4, so that the charging cable 2 in a U-shape has two legs 8, 9 next to one another or above each other, wherein the end of the charging cable 2 carrying the charging plug 3 is deflected downwards in a stationary vertical deflection station 11, so that the charging plug 3 is arranged hanging below the vertical deflection station 11, wherein the guiding device 4 has a deflection unit 16 for U-shaped deflection, which can be displaced in a longitudinal direction of the guiding device and wherein the charging cable 2 is carried and guided by several cable carriers 24 between its connecting end and the deflection unit 16, as well as between the deflection unit 16 and the vertical deflection station 11.