Strain Relief for Cable Hose in EV Charging Connectors
Solution Overview
Problem
Car charging connectors face issues with mechanical stress during frequent bending, leading to twisting and detachment of lines within the cable tube, which can cause electrical and cooling lines to malfunction.
Innovation Solution
A cable hose system with a clamping ring and conductor receiving element that securely holds the cable hose in place, preventing twisting and absorbing tensile forces, while a seal at the cable hose outlet provides protection against dust, water, and mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cable hose is frequently bent during charging processes, then the charging process can be quickly connected and disconnected, but the lines inside the cable tube become twisted and may detach due to mechanical stress
Solution Approach 1:
The cable hose is divided into multiple independent line channels, each containing separate electrical and cooling lines. This segmentation prevents the lines from twisting around each other during bending operations, maintaining connection reliability while allowing frequent charging cycles.
Solution Approach 2:
The lines are nested within individual protective channels inside the cable hose, which itself is nested within the cable tube. This nested structure protects the lines from mechanical stress and twisting during frequent bending, ensuring reliable connections while enabling rapid charging/disconnection.
2Ease of operation
If the cable hose is made more flexible to allow frequent bending, then ease of operation improves, but the lines inside become more susceptible to twisting and detachment
Solution Approach 1:
Different sections of the cable hose have different structural properties. The outer cable hose is made flexible for ease of operation, while the inner line channels maintain a more rigid structure to prevent twisting. This local differentiation allows the cable to be flexible where needed while protecting line positions where required.
Solution Approach 2:
The cable hose uses composite construction with multiple layers and materials - an outer flexible layer for ease of operation and inner structural layers with line channels that maintain geometric stability. This composite structure combines flexibility with line positioning stability, allowing frequent bending without twisting or detachment.
3Reliability
If the lines are tightly secured in the cable hose to prevent twisting, then reliability improves, but the cable hose becomes more complex in structure
Solution Approach 1:
The cable hose is segmented into separate channels for different lines, with each channel providing individual protection and positioning. This segmentation achieves reliable line stabilization through a relatively simple modular structure, avoiding the need for complex securing mechanisms while preventing twisting and detachment.
Data Source
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AI summary
The invention relates to a system consisting of a cable hose outlet which is molded onto a charging connector or attached to a charging station and a cable hose in which electrical cables and/or optical cables and/or coolant-carrying cables can be extended, wherein a conductor receiving element is arranged inside the cable hose which has receptacles for the cables, wherein the cable hose has a clamping ring on the outside which exerts a radial force on the cable hose, whereby the cable hose is pressed onto the conductor receiving element, wherein at least a part of the cable hose runs inside the cable hose outlet and wherein the clamping ring is arranged in a recess inside the cable hose outlet.