Modular Cable Retainer Structure for Variable Charging Cable Diameters
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Solution Overview
Problem
Existing connection systems for electrical vehicle charging cables lack adaptability to varying cable diameters, are difficult to manufacture, and have poor recyclability and compactness, with inadequate cable retention mechanisms.
Innovation Solution
A connection system featuring a modular shell structure with a separate cable retainer having inwardly projecting teeth and a guiding sleeve, allowing for adaptable cable retention and easy manufacturing, along with integrated features for cable retention and exit, and a screwless fixation mechanism, enhancing compactness and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional cable retention system is used, then the structure is simple, but the adaptability to different cable diameters is poor
Solution Approach 1:
The cable retainer is divided into two separate half-shell portions that can be assembled around cables of different diameters. This segmentation allows the retainer to adapt to various cable sizes while keeping each individual component relatively simple in structure.
Solution Approach 2:
The cable retainer is designed with a universal structure that can accommodate multiple cable diameters through adjustable retention elements. The same retainer body can serve different cable sizes by modifying the position or configuration of the retention teeth, achieving multi-functionality without requiring completely different structures for each cable type.
2Reliability
If integrated cable retention features are added, then cable retention is improved, but manufacturing complexity increases
Solution Approach 1:
The cable retention function is segmented into separate retention teeth that can be independently manufactured and then assembled onto the retainer body. This allows the retention features to be optimized for reliability while the base structure remains simple for easy manufacturing.
Solution Approach 2:
The cable retention features are merged with the half-shell portions of the retainer, creating an integrated assembly that provides both structural support and retention functionality. This merging reduces the total number of separate components and simplifies the manufacturing process while maintaining effective cable retention.
3Strength
If a screw fixation system is used, then the connection between half shells is secure, but the design is not compatible with screwless handles
Solution Approach 1:
The screw fixation system is replaced with a mechanical interlocking system using protrusions and recesses between the half-shell portions. This substitution eliminates the need for screws while maintaining strong connections, enabling compatibility with screwless handle designs.
Solution Approach 2:
The connection system is segmented into complementary mating surfaces with interlocking features on each half-shell portion. This segmentation allows each component to be manufactured independently with precise geometric features that engage to provide strong connections without requiring additional fastening elements.
4Ease of operation
If the cable retainer is fixed in position, then the structure is simple, but the cable cannot follow its natural bending
Solution Approach 1:
The cable retainer incorporates flexible or movable elements that allow the cable to bend naturally while maintaining retention. The retention teeth or guiding surfaces are designed to accommodate cable movement and bending without requiring the entire retainer structure to be complex or movable.
Solution Approach 2:
The retainer structure incorporates flexible elements or thin-walled sections that can deform to accommodate the natural bending of the cable. These flexible portions allow the cable to follow its natural path while the overall retainer structure remains relatively simple and maintains its retention function.
Data Source
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AI summary
A connection system (1) for an electrical cable (1000) extending in a longitudinal direction (X), the connection system (1) having: - a shell structure (10) arranged for housing the electrical cable (1000), and extending in the longitudinal direction (X), wherein the shell structure (10) has two half shell portions, having each a mating surface extending in the longitudinal direction (X), and arranged to be clamped with each other in a clamping direction (Z) perpendicular to the longitudinal direction (X), - a cable retainer (30) arranged for retaining the electrical cable (1000), wherein the cable retainer (30) is a separate module arranged inside the shell structure, wherein the cable retainer (30) has at least one tooth projecting inwardly and arranged to retain the electrical cable (1000), the tooth being arranged to be perpendicular with the clamping direction (Z).