Ceiling-Mounted Pulley Cable Routing for EV Charging
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Solution Overview
Problem
There is a need for a simple and convenient cable routing system for electric vehicle charging cables that can be mounted in a residential garage, addressing the limitations of existing systems which often result in cable tangling, tripping hazards, and wear on the cable.
Innovation Solution
A cable routing apparatus comprising a mounting plate attached to the ceiling, a pulley-bracket assembly with pulley wheels and axles, and optional features like a hollow housing member and latch clips, allowing the cable to be easily stored overhead, retrieved, and retracted, keeping the cable off the floor and reducing wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the charging cable is stored on the floor or wall, then it is easily accessible, but it causes tripping hazards, cable wear, and tangling
Solution Approach 1:
The patent moves the cable storage from two-dimensional floor or wall surfaces to three-dimensional overhead space. The cable is routed through ceiling-mounted pulleys and stored in the vertical dimension above the vehicle, eliminating contact with the floor while maintaining accessibility through controlled descent during charging operations
2Ease of operation
If the cable is allowed to drag on the floor during charging, then it is convenient for vehicle connection, but it causes wear and damage to the cable
Solution Approach 1:
The cable is elevated to overhead storage position, preventing floor contact during both storage and charging operations. The cable descends vertically through pulleys to the vehicle connection point, maintaining operational convenience while eliminating abrasive contact with the floor surface that causes wear and damage
3Object-affected harmful factors
If a fixed overhead cable system is used, then cable organization is improved, but the system becomes complex and difficult to install
Solution Approach 1:
The system uses universal ceiling pulleys that can be mounted in various locations and configurations to accommodate different garage layouts. The same basic components serve multiple functions: cable routing, tension management, and organized storage, simplifying the overall system while improving cable organization
Solution Approach 2:
The cable routing system is divided into separate modular segments including ceiling pulleys, cable guides, and connection points. This segmentation allows for simplified installation where each component can be independently mounted and adjusted, reducing overall installation complexity while maintaining effective cable organization
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 a safe, clean, and efficient method for charging electric vehicles by keeping the cable organized, preventing tripping and wear, and allowing easy installation and removal, suitable for various garage layouts.
Implementation Method 1
a pulley-bracket assembly provided for pivotal attachment to the mounting plate, the pulley-bracket assembly including a pulley support member with a pulley support plate, and at least one pulley support arm for attaching to a first side portion of the pulley support plate. The at least one pulley support arm has an end portion with an opening formed therein to receive an end portion of a pulley axle.
Implementation Method 2
The pulley wheel having an arcuate groove extending therearound to receive and support a portion of the cable therein
Data Source
AI summary
A cable routing apparatus, for supporting an electric charging cable, includes a mounting plate and a pulley-bracket assembly, which is pivotally attachable to the mounting plate. The pulley-bracket assembly includes a pulley support member having a pulley support plate and at least one pulley support arm extending downwardly from the support plate. The pulley-bracket assembly further includes a pulley wheel for supporting part of the cable thereon, and a pulley axle extending through a central hub of the pulley wheel. A housing may be provided for covering the pulley-bracket member, and parts of the pulley support member may, optionally, be integrated into the housing. A kit including two of the described cable routing apparatus along with an intermediate pulley bracket and other components, as well as a method of installing the kit in a garage to provide a cable routing system are also described.