Motorized EV Cable Retraction System with Drum and Clutch
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Solution Overview
Problem
Publicly accessible electric vehicle charging stations face challenges in managing and retracting electrical cables efficiently, leading to exposure to elements and tripping hazards when not properly stored, due to the need for reliable and efficient extension and retraction mechanisms.
Innovation Solution
A motorized cable management system with a drum and clutch mechanism allows for automatic retraction and extension of the cable, locking it in a stable coiled configuration within a protective housing when not in use, using a solenoid-controlled clutch and motorized pulley system to ensure secure storage and easy access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the cable is extended for vehicle connection, then connectivity functionality is improved, but cable exposure to elements and tripping hazards increase
Solution Approach 1:
The cable management system transitions from a static fixed installation to a dynamic system with motorized retraction and extension capabilities. The cable can automatically retract into the housing when not in use and extend when needed, adapting its state based on operational requirements while minimizing exposure to harmful environmental factors
Solution Approach 2:
The cable is nested within a protective housing structure that contains a drum mechanism. When retracted, the cable is stored inside the housing, protecting it from external elements. The connector can be accessed by extending the cable from this nested configuration, maintaining protection while enabling connectivity
2Object-affected harmful factors
If the cable is retracted into protective housing, then cable protection is improved, but cable extension and retraction mechanism complexity increases
Solution Approach 1:
The manual mechanical retraction system is replaced with an automated motorized system. A motor driven by a solenoid mechanism automatically winds and unwinds the cable on the drum, eliminating the need for manual handling while providing reliable retraction and extension functionality
Solution Approach 2:
The cable management system performs self-service through automatic retraction when the vehicle disconnects. The motorized mechanism automatically winds the cable back into the housing without user intervention, ensuring the cable is always properly stored when not in use
3Reliability
If motorized retraction system is implemented, then cable management reliability is improved, but system complexity and cost increase
Solution Approach 1:
The system incorporates feedback mechanisms including sensors to detect cable position and vehicle connection status. This feedback controls the motor operation, ensuring reliable automatic retraction when the vehicle disconnects and preventing operation when the cable is already retracted or a vehicle is connected
Solution Approach 2:
A solenoid acts as an intermediary mechanism between the control system and the motor. The solenoid converts electrical signals into mechanical motion to drive the motor, providing a reliable interface that simplifies the control architecture while ensuring dependable actuation of the retraction system
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 effectively keeps the cable protected from the elements and prevents tripping hazards by automatically retracting the cable into a secure position when not in use, ensuring reliable connectivity and maintaining the integrity of the electrical connection.
Implementation Method 1
The clutch mechanism is controlled by a solenoid. Upon de-energizing the clutch solenoid, the clutch gear engages the drive gear.
Implementation Method 2
The drive assembly comprises a motor and a drive gear rotatably connecting with a drive pulley.
Implementation Method 3
The clutch mechanism preferably further comprises a clutch gear, a clutch lever and a spring attached to the clutch lever.
Data Source
AI summary
A system for coiling an electrical cable employed for charging an electric vehicle employs a cable management system. The cable management system has a drive assembly which has a drive mode that retracts the cable and release mode which allows for the cable to be extended. The installation employs a drum having a cylindrical sidewall. The drive assembly drives the cable downwardly into a drum so that the cable progressively engages the sidewall to form a vertical coiled configuration. A clutch assembly cooperates with the drive assembly to provide the automatic retracting and extending operations and also locks the vehicle connector at the end of the electrical cable in an extended position as well as a retracted home position.