EV Charging Arm With Mechanical Fuse for Cable Abuse Loads
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Solution Overview
Problem
Existing electric vehicle (EV) charging stations face challenges with cable management, including messy appearances, tripping hazards, damage risks, and limited flexibility in accommodating different vehicle orientations and additional EVs, due to the use of long, heavy, and often dirty charging cables that are difficult to stow effectively.
Innovation Solution
The EV charging station features a base unit with an arm that supports the charging cable, equipped with a force-limiting mechanism to detach from excessive tension, a pivot joint with a mechanical fuse that indicates and mitigates abuse loads, and a modular EVSE for easy expansion to charge multiple vehicles, along with sensors and a camera for proximity detection and user-friendly installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If long charging cables are used to reach a wide area around the charging station, then the charging station can accommodate vehicles at different orientations and locations, but the cable becomes heavy, messy, and creates tripping hazards when lying on the ground
Solution Approach 1:
The patent applies the dynamics principle by implementing an articulated arm with multiple pivot joints that can dynamically adjust its position and orientation. The arm transitions from a static structure to a dynamic one that follows the cable and vehicle position, allowing the charging station to adapt to different vehicle orientations without requiring long cables to lie on the ground.
Solution Approach 2:
The patent employs dimensionality change by moving the charging cable from a ground-level horizontal arrangement to an elevated spatial arrangement using the articulated arm. This lifts the cable into three-dimensional space, eliminating the tripping hazard and messiness associated with cables lying on the ground while maintaining reach to vehicles at various orientations.
2Reliability
If the charging station structure is made stronger to support higher loads, then it can withstand abuse loads better, but the structure becomes heavier and more complex
Solution Approach 1:
The patent applies beforehand cushioning by incorporating a mechanical fuse that is designed to fail at a predetermined load threshold. This protective mechanism is built in advance to prevent the entire structure from being damaged by excessive abuse loads, allowing the main structure to be lighter while maintaining reliability through the sacrificial protective element.
Solution Approach 2:
The patent uses segmentation by dividing the load-bearing structure into modular components including the base unit, articulated arm sections with pivot joints, and a mechanical fuse. This segmentation allows each component to be optimized independently and simplifies the overall structure while maintaining the ability to withstand abuse loads through the distributed design.
3Ease of operation
If a mechanical retractor is used to support the charging cable off the ground, then cable management is improved, but the system becomes more complex with springs, counterweights, or other mechanical means
Solution Approach 1:
The patent merges the cable support function with the articulated arm structure itself. Instead of using a separate mechanical retractor system with springs and counterweights, the arm structure integrates both the support and positioning functions, eliminating the need for complex retractor mechanisms while achieving the same cable management goals.
Solution Approach 2:
The articulated arm serves multiple functions: it supports the charging cable off the ground, positions the charging plug at the correct location, and provides structural strength to withstand loads. This multi-functionality eliminates the need for separate dedicated cable support mechanisms like retractors, reducing overall system complexity.
4Productivity
If the charging station is designed to accommodate two or more vehicles simultaneously, then charging capacity increases, but the structure and cable management become more complicated
Solution Approach 1:
The patent applies segmentation by designing the charging station with modular articulated arms that can be independently configured for each charging position. Each arm can be adjusted and positioned independently, allowing multiple vehicles to be charged simultaneously without creating a monolithic complex structure. The modular design simplifies installation and maintenance.
Solution Approach 2:
The patent uses dynamics by implementing adjustable and reconfigurable articulated arms that can adapt their position and configuration based on the number and orientation of vehicles being charged. This dynamic capability allows the station to accommodate 2-3 vehicles simultaneously while maintaining simple cable management through the flexible arm positioning.
Data Source
AI summary
Charging stations for electric vehicles may include arms that extend from a structure to allow easy deployment of a charging plug to a charging receptacle on an electric vehicle. The arms may be pivotally connected to the structure. Charging cables may be attached to the arms by a break away construction. Arms may include mechanical fuses that deform or break when excessive forces are applied to the arms. These features of construction can help to protect the charging station and charging cable from damage. Charging stations may include other features including lighting, motion sensors, cameras, and suspended plug cradles.