Flexible Overhead Cable Support for EV Charger Connector Protection
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Solution Overview
Problem
Charging cables for electric vehicles are prone to damage, freezing, and are cumbersome due to their length, especially for high-power charging, which requires careful management to prevent damage and ensure efficient connection.
Innovation Solution
A cable support mechanism that supports the charging cable and connector from above, using a flexible support member that bends to facilitate connection and prevents the connector from falling, combined with a base for stable support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the charging cable is made longer to reach charging sockets on any vehicle position, then the adaptability is improved, but the cable becomes susceptible to damage and freezing
Solution Approach 1:
The cable support mechanism introduces a vertical dimension to cable management by supporting the cable from above at multiple heights, transforming the traditional horizontal ground-laying arrangement into a three-dimensional suspended configuration that clears the ground while maintaining cable length for vehicle accessibility
2Reliability
If the charging cable is made shorter to reduce losses and improve maneuverability, then the reliability is improved, but the adaptability to reach different vehicle positions deteriorates
Solution Approach 1:
The cable support mechanism employs movable and adjustable support members that can dynamically reposition along the cable's length and adjust their height, enabling the system to adapt to different vehicle positions while maintaining optimal cable tension and minimizing unnecessary cable length on the ground
3Reliability
If the charging connector is supported from above to prevent falling, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The cable support mechanism utilizes the cable's own weight and tension to activate the support function - when the cable sags under its own weight, it naturally contacts the support members, which then provide upward support without requiring active sensing or control systems, allowing the system to self-regulate and prevent connector drops
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
Prevents damage to the charging cable and connector, maintains efficient connection, and ensures alignment with the vehicle socket, even in challenging conditions.
Implementation Method 1
the support member (3, 4) is reversibly flexible in a transverse direction (7) in relation to the upwards direction of the first use position in a second use position of the cable support mechanism (1), wherein in the second use position an external force directed away from the base (2) is applied to a distal end (8) of the support member (3, 4)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A cable support mechanism (1) for an electric vehicle charging station (30) comprises a base (2) and a support member (3, 4). The support member (3, 4) has an elongated shape comprising a proximal end (5) and a distal end (8) provided at opposite ends of the support member (3, 4). The support member (3, 4) is fixedly mounted to and supported by the base (2) at the proximal end (5) of support member (3, 4). The support member (3, 4) is arranged to extend upwards from the base (2) at the proximal end (5) in a first use position of the cable support mechanism (1), in which first use position no external force is applied to the cable support mechanism (1). The support member (3, 4) is reversibly flexible in a transverse direction (7) of the support member (3, 4) in such a manner that at least a part of the support member (3, 4) bends in a transverse direction (7), wherein an external force directed away from the base (2) is applied to a distal end (8) of the support member (3, 4), and returns to the position extending upwards from the base (2), when the external force is no longer applied to the cable support mechanism (1).