Overhead EV Charger Cable Routing to Prevent Damage and Trips
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Solution Overview
Problem
Conventional EV charger cable management systems expose long EV charger cables to damage and create tripping hazards, as they are typically not managed effectively, especially in installations without a pedestal or wall-mounted chargers, leading to cable exposure during use and storage.
Innovation Solution
An overhead EV charger cable management system that includes a junction box affixed to the ceiling via a bracket, with optional retractor and trolley mechanisms to suspend and manage the EV charger cord set, keeping it out of the user's and vehicle's path, allowing for flexible charging without relocating the vehicle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the EV charger cable is made long (at least 7.5 meters) to allow flexible charging locations, then the charging flexibility is improved, but the cable becomes more exposed to damage and tripping hazards
Solution Approach 1:
The patent transitions the cable management from ground level to overhead suspension, utilizing the vertical dimension. The cable is routed through the vehicle and suspended above the ground, keeping it out of the tripping zone while maintaining full length for charging flexibility. This dimensional change resolves the contradiction by elevating the cable away from harmful ground-level factors.
Solution Approach 2:
The vehicle itself serves as an intermediary element in the cable management system. The cable passes through the vehicle interior, using the vehicle structure as a protective conduit and routing mechanism. This intermediary approach protects the cable from external damage while enabling flexible positioning without ground-level hazards.
2Adaptability or versatility
If the EV charger is installed remotely in a power panel without a pedestal or wall-mounted charger, then the installation flexibility is improved, but the cable management becomes more complex and challenging
Solution Approach 1:
By routing the cable overhead through the vehicle and suspending it above ground level, the system simplifies remote installations by eliminating the need for pedestal or wall-mounted chargers. The overhead configuration provides natural cable management without adding complex ground-level routing structures.
Solution Approach 2:
The vehicle structure itself provides the cable routing and management function. The cable passes through the vehicle interior and is suspended overhead, using the vehicle's own structure to manage the cable rather than requiring separate management systems. This self-service approach reduces overall system complexity.
Data Source
AI summary
An electric vehicle (EV) charger cable management system for use at an EV charging facility coupled to a power source via an EV charger is provided. The EV charger cable management system includes an EV charger cord set including an EV connector and an EV charger cable coupled to the EV connector; a bracket; and a junction box coupled to the EV charger cable and including electrical wirings, the junction box being structured to electrically connect the EV charger to the EV charger cord set via the electric wirings, be affixed to a portion of top surface of the EV charging facility via the bracket, and maintain a majority of the EV charger cord set to be suspended overhead and out of a path of a user or the EV.