Holster Sensor for Electric Vehicle Charging Cable Management
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Solution Overview
Problem
Field service data shows that broken cables connecting charge couplers to dispensers in electric vehicle charging infrastructure account for a majority of service visits and replacement costs, often due to improper handling and exposure to inclement weather, leading to electrical shorts and physical damage.
Innovation Solution
The implementation of an electrical power dispenser system with a holster sensor that detects the presence of a charge coupler, generating a signal indicative of its position, and a user light to provide visual feedback, helping to prevent cables from being left on the ground and reducing strain on the cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cable is shortened to reduce damage risk, then the charge coupler may be suspended above ground when not in use, but this creates undue stress and strain on the cable due to its weight being supported only by the physical connection
Solution Approach 1:
The patent applies the anti-weight principle by introducing a support structure (holster with sensor system) that counteracts the weight of the charge coupler and cable when suspended. The holster provides a resting position that supports the weight, preventing the cable from bearing the full stress of the suspended charge coupler, thereby reducing cable stress while maintaining cable durability
2Ease of operation
If the charge coupler is left hanging freely or on the ground, then it is easily accessible for use, but it becomes exposed to inclement weather, water, snow, and vehicle traffic, leading to electrical shorts and physical damage
Solution Approach 1:
The patent applies preliminary action by providing a pre-configured holster position that automatically receives and protects the charge coupler when not in use. The holster is positioned to naturally guide the charge coupler into a protected state, and the sensor system proactively monitors and alerts when the charge coupler is misplaced, preventing exposure to harmful environmental factors before damage occurs
Solution Approach 2:
The patent implements feedback through the sensor system that detects whether the charge coupler is properly positioned in the holster. The sensor provides real-time information about the charge coupler's position and condition, enabling the system to alert users or automatically take corrective actions to prevent environmental damage while maintaining ease of operation
Data Source
AI summary
Various disclosed embodiments include illustrative electrical power dispensers for electrical vehicle charging systems, charging systems, and methods of sensing presence of a charge coupler in a holster of an electrical power dispenser. In an illustrative embodiment, an electrical power dispenser for an electrical vehicle charging system includes a housing. A charge coupler is configured to dispense direct current electrical power. A holster is disposed on the housing and is configured to receive the charge coupler therein. A holster sensor is configured to sense presence of the charge coupler in the holster and is further configured to generate a signal indicative of presence of the charge coupler in the holster.