Precast Cable Routing Block for Fast EV Charger Base Installation
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Solution Overview
Problem
Existing methods for routing underground electrical power cables to above-ground installations, such as electric vehicle charging stations, are inefficient, requiring specialized installation, deep trenches, and lack flexibility in fastening arrangements, leading to instability and difficulty in maintenance.
Innovation Solution
A preformed block with integrated conduits and a removable adaptor plate allows for routing cables without trenching, providing a stable base and adaptable fastening, enabling quick installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If wet concrete is poured into the trench to form the base, then a solid base is created to support the electrical installation, but the installation cannot proceed until the concrete cures for 24-48 hours and the process is limited to favourable weather conditions
Solution Approach 1:
The base is segmented into preformed concrete blocks with integrated cable access features, eliminating the need for pouring and curing a continuous concrete base. The blocks are manufactured off-site and assembled quickly on-site, reducing installation time from days to hours while maintaining structural strength.
Solution Approach 2:
The concrete blocks are prepared in advance with pre-formed cavities, conduits, and cable access points during manufacturing. This preliminary action eliminates on-site concrete pouring and curing time, allowing immediate installation of the electrical installation once blocks are assembled.
2Ease of operation
If standard CMUs with vertical holes are used to route cables, then cables can be directed through the block, but a deep trench is required beneath the block which disturbs ground stability and requires specialized installation
Solution Approach 1:
Instead of routing cables vertically through the block from below (requiring deep trenches), the invention provides cable access through side openings in the vertical faces of the blocks. This lateral cable access eliminates the need for deep trenches beneath the base, maintaining ground stability while enabling easy cable routing.
3Strength
If drilling holes and embedding fastenings into the concrete base is used to attach the electrical installation, then secure attachment is achieved, but the integrity of the concrete is reduced and the fastening configuration cannot be changed
Solution Approach 1:
The fastening system is segmented into removable fastenings that can be detached and reconfigured. Instead of permanently embedding fastenings into the concrete base, the invention uses detachable fastening mechanisms that allow the electrical installation to be removed, repositioned, or reconfigured without damaging the base structure.
Solution Approach 2:
The fastening system transitions from a static, permanent embedding to a dynamic, removable connection. The fastenings can be engaged and disengaged as needed, allowing flexible reconfiguration of the electrical installation while maintaining secure attachment during operation.
4Ease of manufacture
If hand-made shuttering is used for each base, then the base can be formed on site, but the size and finish vary from base to base depending on operative skill
Solution Approach 1:
The base is divided into standardized, preformed concrete blocks with consistent dimensions and features manufactured in a controlled environment. This segmentation into uniform modules eliminates the variability inherent in hand-made on-site shuttering while maintaining on-site assembly flexibility.
Solution Approach 2:
Instead of creating unique bases through hand-made shuttering for each location, the invention uses replicated preformed blocks with standardized dimensions and features. These copies ensure consistent quality, size, and finish across all installations while simplifying on-site assembly.
Data Source
AI summary
A preformed block is used for housing and routing electrical power cables, and comprises a central cavity. At least two adjacent faces of the block have an opening which connects to the central cavity. Electrical power cables can thus be routed within the block between those openings, from a side face (leading to a trench) to the top face (leading to an electrical installation on top). There is also provided an electric vehicle charging station using the precast block and a method of casting a block.