Liquid-Cooled Cable Feeding Arrangement for Electric Vehicles
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Solution Overview
Problem
Existing cable feed arrangements for electric vehicles face challenges such as heavy, inflexible cables that are prone to damage, require large cross-sections for high current transmission, and often result in tripping hazards and space constraints, limiting efficient charging times and handling.
Innovation Solution
A cable feed system with a support arm and trolley that elevates the electrical line above the vehicle, allowing horizontal displacement to connect from above, combined with liquid cooling to reduce cable weight and increase flexibility, enabling higher current transmission without ground contact and minimizing handling difficulties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the cable cross-section is increased to transmit larger currents for short charging times, then the current transmission capability is improved, but the cable weight and handling difficulty increase
Solution Approach 1:
The patent applies liquid cooling technology to the cable, using a cooling medium circulating through channels in the cable to dissipate heat generated during high-current charging. This allows the cable to sustain higher currents without thermal damage, enabling increased power transmission capability while managing the thermal load that would otherwise require even larger cross-sections
Solution Approach 2:
The patent changes the thermal parameter of the cable by implementing active cooling, which allows the cable to operate at higher temperatures continuously. This parameter change enables the use of smaller cross-sections for the same power transmission capability, or alternatively allows higher currents through the same cross-section while managing thermal constraints
2Power
If the cable cross-section is increased to transmit larger currents, then the current transmission capability is improved, but the cable flexibility and ease of handling deteriorate
Solution Approach 1:
The liquid cooling system is integrated into the cable structure with cooling channels and pump units, allowing the cable to maintain higher temperatures during operation. This thermal management enables the use of smaller, more flexible cables that can transmit high currents without becoming excessively rigid and difficult to handle
Solution Approach 2:
The cable employs a composite structure combining conductive material with integrated cooling channels and insulation layers. This composite design allows optimization of both electrical conductivity and mechanical flexibility, enabling high current transmission while maintaining ease of handling through thoughtful material integration
3Ease of operation
If the cable is made flexible and lies on the ground for easy handling, then the ease of operation is improved, but the cable reliability and resistance to damage deteriorate
Solution Approach 1:
The patent transitions the cable from a ground-level arrangement to an aerial suspension system using a support arm and trolley mechanism. The cable is suspended above the ground and can be positioned vertically or at angles, eliminating contact with the ground and associated damage risks while maintaining operational flexibility through the movable support system
Solution Approach 2:
The support arm and trolley act as intermediary mechanisms between the fixed charging station and the vehicle. These intermediaries carry and position the cable in space, allowing the cable to remain suspended and protected while still enabling easy connection and disconnection operations
4Productivity
If the charging station is installed near the vehicle for efficient charging, then the charging efficiency is improved, but the station stability and protection from vehicle impact deteriorate
Solution Approach 1:
The charging infrastructure is moved from ground level to aerial suspension using support arms and trolleys that can extend over the vehicle. This vertical and horizontal positioning in three-dimensional space allows the charging point to be close to the vehicle connector while the main station structure remains stable and protected at a distance
5Adaptability or versatility
If a long charging cable is used to reach the vehicle when the station cannot be installed nearby, then the adaptability is improved, but the cable poses tripping hazards and handling difficulties increase
Solution Approach 1:
The cable is suspended aerially on a movable support arm with a trolley that can traverse along the arm. This three-dimensional positioning system provides extensive reach and flexibility without requiring a long ground-level cable, eliminating tripping hazards and reducing handling difficulty by keeping the cable elevated and organized
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
This solution allows for safer, more efficient charging with reduced cable damage and improved maneuverability, enabling 30-50% more current transmission with the same cross-section, facilitating quicker battery charging without compromising handling, and reducing downtime and obstacles during vehicle operation.
Implementation Method 1
cooling cables is a known method. This allows the cross-section of the metallic cable to be reduced, thereby also lowering its weight
Data Source
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AI summary
The invention relates to a line supply arrangement for electrically driven motor vehicles comprising an electric line (4) for charging an energy store of the motor vehicle and a support arm having a crab (3) for positioning the line (4). The support arm (4) can be displaced in the horizontal direction and/or the crab (3) can be displaced relative to the support arm (2) in the horizontal direction. The crab (3) is located at a height above the motor vehicle to be charged. A free end (5) of the conduit (4) hangs down from the crab (3) on the support arm (2) in order, coming from above, to be connected to the motor vehicle for charging. The conduit (4) is liquid-cooled.