EV Cooling Cable Reel for Automated Pay-In and Pay-Out
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Solution Overview
Problem
Existing cooling systems for electric vehicles are cumbersome and time-consuming due to messy cable solutions and the need for manual pay-in and pay-out of heavy cooling cables, which decreases user appeal and efficiency.
Innovation Solution
A system with a cooling cable and connector featuring a rotation mechanism, cable reel with a helical pattern, and idler drum for automated pay-in and pay-out, simplifying the process and reducing manual effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual cable management is used, then device complexity is reduced, but ease of operation deteriorates due to cumbersome manual pay-in and pay-out of heavy cooling cables
Solution Approach 1:
The cable reel system automatically pays out and retracts the cooling cable without requiring manual intervention. The rotation mechanism self-regulates cable deployment based on connector position, eliminating the need for users to manually handle the heavy cable while maintaining operational simplicity
Solution Approach 2:
The cable reel transitions from a static cable storage system to a dynamic automated system. The rotation mechanism adjusts cable length in real-time based on the connector's position relative to the electric vehicle, providing adaptive cable management that improves ease of operation without excessive complexity
2Productivity
If automated cable management system is implemented, then ease of operation improves, but device complexity increases due to rotation mechanism and cable reel components
Solution Approach 1:
The cable reel system serves multiple functions: it stores the cooling cable, controls cable deployment length, guides cable positioning, and enables automated pay-in/pay-out operations. By consolidating these functions into a single integrated mechanism, the system improves productivity without proportionally increasing overall device complexity
Solution Approach 2:
The cable reel acts as an intermediary between the cooling system and the electric vehicle connector. It mediates cable delivery, ensuring proper tension and positioning while protecting the heavy cable from damage, thereby improving operational efficiency without requiring complex separate systems for each function
3Reliability
If heavy cooling cable is used for effective cooling, then cooling performance is maintained, but ease of operation deteriorates due to manual handling difficulty
Solution Approach 1:
The rotation mechanism automatically manages the heavy cooling cable throughout the connection process. It self-adjusts cable deployment based on connector position and automatically retracts the cable after use, eliminating manual handling of the heavy cable while maintaining the necessary cable mass for effective cooling performance
Data Source
AI summary
A system of pay-in and pay-out function of a cooling system for an electric vehicle and a method of use is presented in this disclosure. The system may include a cooling cable, a cooling connector, wherein the cooling connector may include an actuator, a cable reel, and an idler drum. The cable reel may include a helical pattern where the cooling cable resides during the stowed configuration. The idler drum may be parallel to the cable reel.