EV Charging Cable Retraction to Reduce Connector Tension
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Solution Overview
Problem
Current electric vehicle charging systems lack efficient and safe cable management, leading to cable wear, safety hazards, cluttered charging stations, and difficulties in locating available charging connectors due to inadequate tension management.
Innovation Solution
A cable tension management system that includes a tension reducing device with a flexible support and clamping element, attached to a wall or support beam, which reduces or eliminates tension on the charging connector by suspending the weight of the connector and automatically retracting it into a tension reducing device after charging is complete.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional manual cable management methods are used, then users can handle and store charging cables, but cable wear and tear occurs, creating safety hazards and reducing reliability
Solution Approach 1:
The system employs an automatic cable retraction mechanism that autonomously winds and stores the charging cable after use, eliminating manual handling operations. The motor-driven spool automatically reels in the cable, preventing user-induced wear and tear while maintaining operational convenience
Solution Approach 2:
A motorized spool mechanism serves as an intermediary between the cable and the user, mediating the cable management function. This intermediary automatically controls cable deployment and retraction, protecting the cable from manual mishandling while enabling easy operation
2Ease of operation
If manual cable storage is used, then users can store cables after charging, but cluttered charging stations and tripping hazards occur, worsening safety and accessibility
Solution Approach 1:
The automatic retraction system performs cable storage autonomously without user intervention. After charging completes, the motor-driven spool automatically winds the cable back into a compact housing, eliminating clutter and tripping hazards while maintaining ease of operation
Solution Approach 2:
The cable is extracted from the chaotic manual storage environment and integrated into a controlled automatic retraction system. The cable is taken out of the user's hands and managed by an automated mechanism, removing it from the charging station environment after use to prevent clutter
3Stability of the object's composition
If tension is applied to the charging connector during charging, then the cable remains taut and connected, but cable wear and connector damage occur, reducing reliability and increasing harmful factors
Solution Approach 1:
The motorized spool applies a counter-tension force to balance and neutralize the gravitational weight of the cable. This counterweight mechanism prevents excessive tension on the connector by actively managing cable tension throughout the charging process, maintaining connection stability while protecting against wear
4Ease of operation
If the charging connector is left accessible after charging, then users can easily access it, but safety hazards and clutter increase
Solution Approach 1:
The system automatically retracts the cable and connector into the housing after charging completes, performing the safety function autonomously. This self-service action removes the connector from public access areas, eliminating safety hazards while maintaining ease of operation during active charging
Solution Approach 2:
The automatic retraction mechanism takes preliminary action to prevent safety hazards by retracting the connector before users can encounter it. This preemptive measure eliminates potential tripping hazards and electrical safety risks associated with exposed connectors
Data Source
AI summary
A system may be provided for cable tension management for charging an electric vehicle (EV) located proximate a power source attached to a first wall, a first support, or a first support beam, and a charging connector comprising a charging portion configured to be electrically connected to the power source, and a connection portion comprising an EV outlet charging interface configured to removably engage an EV inlet charging interface. The system may include a tension reducing device, attached to a second wall, a second support, or a second support beam, including a flexible support and a clamping element. The clamping element may be configured to couple the flexible support to the charging connector between the charging portion and the connection portion.