EV Charger Cable Management with Sensor-Controlled Roller System
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Solution Overview
Problem
Existing electric vehicle rapid chargers face challenges in usability for weaker users, as they require significant effort to handle thick and heavy charging cables, and there is a risk of cable damage and contamination due to contact with the ground, especially in ultra-rapid or rapid charging systems.
Innovation Solution
An electric vehicle rapid charger with a sensor-controlled automatic discharger-collection system that includes rotating rollers and guide pins to manage the charging cable, preventing ground contact and allowing for easy discharge and collection without external force, using a sensor module to sense cable length and connection states for automated operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a thick and heavy charging cable is used for rapid charging, then power transmission capability is improved, but ease of operation deteriorates
Solution Approach 1:
The charging cable system performs self-service through automatic winding and unwinding mechanisms. The cable automatically winds itself onto the reel after use and unwinds when needed, eliminating the need for manual handling by users regardless of cable thickness and weight.
Solution Approach 2:
The manual mechanical handling of the cable is replaced with an automated mechanical system consisting of a motor-driven reel, sensor detection, and control circuits. This substitution allows thick cables to be managed automatically without requiring user physical effort.
2Ease of operation
If the charging cable is allowed to contact the ground for easy handling, then ease of operation is improved, but reliability deteriorates
Solution Approach 1:
The cable management system transitions the cable from a ground-level position to an elevated position on the reel mechanism. By changing the spatial dimension from ground contact to suspended storage, the system simultaneously achieves easy handling through automatic operation while preventing ground contact that would compromise safety.
Solution Approach 2:
The harmful element (ground contact) is extracted from the system by elevating the cable storage position. The cable is taken out from the ground environment and stored on the reel mechanism, eliminating contamination and damage risks while maintaining operational convenience through automation.
3Reliability
If a spring balance is used to prevent cable ground contact, then reliability is improved, but ease of operation deteriorates
Solution Approach 1:
The passive mechanical spring balance system is replaced with an active automated control system. Instead of relying on spring tension to prevent ground contact, the system uses sensors to detect cable position and motor control to automatically wind/unwind the cable, eliminating the need for users to overcome spring force while maintaining safety.
Solution Approach 2:
The cable management system becomes self-regulating through automated control. The sensor detects cable position and the motor automatically adjusts winding to maintain proper cable tension and position, eliminating the need for user intervention to overcome spring balance forces.
4Reliability
If the charging cable is continuously pulled by a spring balance, then reliability is improved, but the cable durability deteriorates
Solution Approach 1:
The cable winding operation transitions from continuous spring balance tension to periodic motor-driven winding. The motor winds the cable only when needed (after use or when fully extended), rather than continuously pulling it, reducing cumulative stress and fatigue on the cable while maintaining connection stability.
Solution Approach 2:
The continuous mechanical pulling force of the spring balance is replaced with intermittent motor-driven winding. The motor applies force only during winding operations controlled by sensors, eliminating continuous tension that causes cable fatigue and extends service life while maintaining connection reliability.
Data Source
AI summary
The present disclosure relates to an electric vehicle rapid charger equipped with a sensor for controlling an automatic pull-out of a charging cable. The electric vehicle rapid charger according to an embodiment of the present disclosure includes: a main body including a connector holder provided on one side of the main body and a cable connection part provided at a first predetermined height; a cable inlet/outlet part including a plurality of rotating rollers and fixedly coupled to the main body at a second predetermined height; a charging cable having a leading end portion in which a connector connected to a connection inlet of an electric vehicle is provided, a rear end portion fixedly coupled to the cable connection part, and an intermediate portion coupled to the cable inlet/outlet part to be inserted between the plurality of rotating rollers; and a control part configured to control a driving of the cable inlet/outlet part according to a charging request signal or a charging stop signal. The cable inlet/outlet part includes guide pins arranged on a front side or a rear side of the plurality of rotating rollers to guide the charging cable to move between the plurality of rotating rollers at a normal position, and is configured to continuously discharge or collect the charging cable by a driving of the plurality of rotating rollers.