Polygonal Cable Positioner Prevents Rotation in Chargers
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Solution Overview
Problem
Existing charger technologies fail to effectively prevent cable rotation and disconnection between conducting terminals and welding points, leading to reduced cable installation efficiency and lifespan.
Innovation Solution
A cable positioning device with a polygonal column that deforms non-elastically to securely fit the cable, featuring abutment surfaces against the mounting structure to prevent rotation and axial displacement, ensuring stable connection of the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If protruding wall members are used to secure the transmission line by friction, then the transmission line is held in place, but the transmission line can still rotate and vibration is not sufficiently reduced
Solution Approach 1:
The cable positioning device features an irregular inner surface with locally varied friction characteristics. The surface includes protrusions and recesses that create different friction zones along the cable circumference, preventing rotation while maintaining axial positioning. This local quality variation transforms the uniform friction approach into a multi-zone friction system that effectively prevents both movement and rotation.
Solution Approach 2:
The cable positioning device employs an asymmetric irregular surface pattern rather than symmetric protrusions. The irregular surface creates uneven friction distribution that naturally prevents rotational movement. The asymmetric design ensures that no matter how the cable is oriented, the friction forces will resist rotation, solving the limitation of symmetric protruding wall members.
2Stability of the object's composition
If elastic rubber packing members are used to attach the cable periphery and force the cable along the curving direction, then cable rotation is avoided, but cable installation efficiency is greatly reduced
Solution Approach 1:
The cable positioning device is pre-installed in the charger housing before cable installation. The irregular surface structure is already in place to guide and position the cable. This preliminary action eliminates the need for workers to manually attach rubber packing members and force cables along curving paths, significantly improving installation efficiency while maintaining rotation prevention.
Solution Approach 2:
The cable positioning device's irregular surface automatically guides the cable into the correct position and orientation as it is inserted. The cable itself serves to activate the positioning function - simply inserting the cable causes it to engage with the irregular surface, which then prevents rotation. This self-service mechanism eliminates complex manual positioning operations.
3Reliability
If the charger structure is designed to withstand thousands of plugging and unplugging operations, then connection reliability is improved, but cable installation complexity increases due to the need for additional protective measures
Solution Approach 1:
The cable positioning device integrates multiple functions into a single component: it provides mechanical support for the cable, prevents rotation through its irregular surface, guides cable insertion along the correct path, and protects the cable from stress during plugging and unplugging operations. This merging of functions reduces the number of separate components needed and simplifies the overall installation process while maintaining high reliability.
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
The solution effectively prevents cable rotation and disconnection, enhancing installation efficiency and prolonging the charger's lifespan by securely attaching the cable to the charger's mounting structure.
Implementation Method 1
The column can be forced by an external pressure to deform non-elastically, and to further tightly fit the cable
Implementation Method 2
the attaching force produced from the abutment between the peripheral surfaces of the column of the cable positioning device and the inner walls of the mounting structure effectively prohibits the cable from rotation
Data Source
AI summary
A cable positioning device and a charger using the cable positioning device is disclosed to include a cable positioning device mounted in a mounting structure inside the charger to secure a cable. The cable positioning device includes a polygonal column that can be forced by an external pressure to deform non-elastically and to further tightly fit the cable, having at least one surface thereof abutted against an inner wall of the mounting structure in the axial direction of the cable to prevent displacement of the cable positioning device and the internal electric wires of the cable due to accidental twisting of the external part of the cable, improving the cable installation efficiency.