EV Charging Cable Control Mechanism for Retraction and Locking
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Solution Overview
Problem
Electric vehicle charging stations face issues with long charging cables causing handling difficulties, damage, and safety concerns due to improper winding and retraction, with existing solutions like spring-shaped cables not fully addressing these problems.
Innovation Solution
A control mechanism for the charging cable, including a load balancer device with a locking system, that allows the cable to be safely extended during use and retracted automatically after charging, preventing unwanted stress and damage, and ensuring the cable is not active during charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the charging cable is made longer to allow parking at greater distances, then the ease of operation is improved, but the cable becomes more prone to damage and handling difficulties increase
Solution Approach 1:
The system performs preliminary actions by automatically retracting the cable to a safe position before the charging session ends, and by providing visual warnings before the cable is fully retracted. This prevents the cable from being left in a vulnerable state on the ground where it could be damaged by vehicle movement.
Solution Approach 2:
The system uses feedback through visual indicators (LED lights) to communicate cable status to the user. The first LED indicates when the cable is in a vulnerable position, and the second LED warns when full retraction is imminent, allowing the user to respond appropriately to prevent damage.
2Ease of operation
If a spring-shaped cable is used to enable automatic retraction, then the cable repositioning is improved, but the cable cross section becomes too large and pulling effort increases
Solution Approach 1:
The system replaces the spring-based mechanical recall mechanism with an electric motor-driven reel system. This substitution allows for a more compact cable construction without the need for a large-diameter spring, reducing the cable cross-section and making it easier to handle while plugging and unplugging.
Solution Approach 2:
The system uses a motor that can dynamically adjust its operation - running during charging to maintain cable position, and automatically retracting after charging ends. The locking mechanism provides dynamic control, engaging to hold the cable during charging and disengaging to allow automatic retraction afterward.
3Ease of operation
If the cable is automatically retracted at any stage, then the cable management is improved, but stress is applied to the cable and connector during charging which is undesirable
Solution Approach 1:
The system dynamically controls the locking mechanism and motor based on charging status. During active charging, the lock engages to prevent automatic retraction, ensuring the cable remains stable and free of stress on the connector. After charging completes, the lock disengages and the motor automatically retrieves the cable, providing excellent cable management at the appropriate time.
Solution Approach 2:
The system uses feedback from the charging status to control cable management actions. The base station detects when charging is active and prevents retraction, and automatically initiates retraction when charging completes, ensuring cable management actions occur only when appropriate and safe.
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 solution effectively manages the length and retraction of the charging cable, reducing user effort, preventing damage, and ensuring safety by allowing the cable to be freely moved during charging and automatically retracted after use, thus addressing the handling and safety issues of existing systems.
Implementation Method 1
at least one magnet steel blade (6) and (at least) an electromagnet (7) coupled to the magnet steel blade, wherein the electromagnet (7) is driven by the base station (1a)
Implementation Method 2
the magnet steel blade (6) is locked by the electromagnet (7)
Data Source
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AI summary
It is disclosed an electric vehicle charging station (1) including a base station (1a), a charging cable (2) having an end (2a) electrically connected to the base station (1a) inside the base station (1a), and a free end (2b) adapted to be connected to an electric vehicle for recharging. A load balancer device (3) including a second cable (8) and a locking system (4) is provided, the second cable (8) being structurally associated to the charging cable (2) and the locking system (4) being configured to lock retraction or extension of the second cable (8) in a first operating state and to unlock retraction or extension of the second cable (8) in a second operating, the base station (1a) being configured to drive the locking system (4) in the first or second operating state. It is also disclosed a method and a system for controlling use of a cable or tube, for other applications.