Rotatable Bus Bar Charging Arm for Heavy EV Cables
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Solution Overview
Problem
High-power liquid cooled charging cables for electric vehicles are heavy and stiff, making them difficult to handle and connect, and existing robotic systems are expensive and potentially dangerous.
Innovation Solution
A force assisted charging arrangement using rotatable bus bars and a charging cable system that absorbs the weight of the cable, allowing easy handling and connection to vehicles without lifting, with the cable hanging vertically and rotatable around a vertical axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If liquid cooled charging cables are used for high-power charging, then the charging cable can carry high current (500A at 1000V) with thinner conductors, but the charging cable becomes very stiff and heavy
Solution Approach 1:
The charging cable system is made dynamic through the rotatable connection at the bus bar assembly, allowing the cable to rotate and move freely around a vertical axis. This dynamic configuration enables the heavy cable to be positioned conveniently without manual lifting, resolving the contradiction between high power capability and heavy weight by making the system adaptable rather than static
2Power
If liquid cooled charging cables are used for high-power charging, then the charging cable can carry high current (500A at 1000V) with thinner conductors, but the charging cable becomes very stiff
Solution Approach 1:
The rotatable bus bar assembly provides dynamic positioning capability, allowing the stiff cable to be rotated into the correct position automatically without requiring manual manipulation. The cable hangs vertically from the rotatable connection, making connection to the vehicle straightforward despite the cable's stiffness
Solution Approach 2:
The system uses the vertical hanging configuration where the cable's own weight creates a natural downward force, positioning the connector at an accessible height. This counteracts the handling difficulty by using gravity to assist positioning rather than requiring manual lifting against the cable's weight
3Ease of operation
If robotic systems are used to handle charging cables, then the disadvantages of heavy and stiff cables are overcome, but the system becomes expensive and potentially dangerous
Solution Approach 1:
The charging system serves itself by using the rotatable bus bar assembly to automatically position the cable connector without requiring external robotic assistance. The cable hangs vertically and can be rotated into position, making the system self-configuring and eliminating the need for complex robotic handling mechanisms
Data Source
AI summary
A force assisted charging arrangement for supplying electrical energy to an electrical vehicle includes: a first set of bus bars arranged distant and fixed in respect to ground; a second set of bus bars having a first end and a second end, the first end being rotatably connected to the first set of bus bars so as to allow a rotation of the second end around a vertical rotation axis; a charging cable having a first charging cable end and a second charging cable end, the second charging cable end being connected to the second end of the second set of bus bars; and a charging connector connected to the first charging cable end.