Split Cable Clamp with Curved Exit for EV Charging
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Solution Overview
Problem
Electric vehicle charging cables and connectors are prone to damage due to unexpected high forces, such as vehicle runaways, leading to potential safety issues and equipment failure.
Innovation Solution
A split cable clamp made of rigid plastic, designed to securely grip the charging cable at the exit point of the charging station with a curved portion forcing the cable to exit at a predetermined angle, featuring internal ribs for additional grip and fasteners to prevent impingement, ensuring the cable is not pinched and maintaining coolant flow in liquid-cooled cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional rigid clamp is used to secure the charging cable, then the cable is firmly held in place, but the cable may be impinged or damaged due to overtightening
Solution Approach 1:
The clamp is divided into two separate clamping pieces that can be independently adjusted and secured. This segmentation allows each piece to apply pressure evenly without concentrating force at single points, preventing cable impingement while maintaining secure holding strength
Solution Approach 2:
The clamping pieces are designed with curved portions that change the geometric parameters of the clamp-cable interface. The curvature distributes the clamping force along the cable surface, preventing localized impingement damage while maintaining adequate holding strength
2Adaptability or versatility
If the cable is allowed to exit at any angle, then installation is flexible, but the cable experiences increased stress and potential damage
Solution Approach 1:
The clamp is pre-configured with curved portions that establish a predetermined optimal exit angle for the cable. This preliminary geometric configuration guides the cable through the charging station at the correct angle, preventing excessive stress and damage before the cable even begins its path
Solution Approach 2:
The curved portions of the clamping pieces create a smooth, rounded path for the cable to follow. This curvature eliminates sharp angles and stress concentration points, allowing the cable to exit at the predetermined angle with minimized stress while maintaining installation flexibility
3Stability of the object's composition
If fasteners are used to secure the clamping pieces, then the clamp structure is stable, but overtightening may damage the cable
Solution Approach 1:
The clamp structure is segmented into two independently adjustable clamping pieces, each secured by its own fasteners. This allows the fasteners to secure the clamp structure stably without requiring excessive tightening force, as each piece can be adjusted to the correct position independently, preventing cable damage from overtightening
Solution Approach 2:
The curved portions of the clamping pieces act as intermediaries between the fasteners and the cable. They translate the securing action of the fasteners into a distributed, gentle pressure on the cable, maintaining clamp stability while preventing direct transmission of overtightening forces to the cable
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 cable clamp effectively reduces stress on the charging cable, preventing damage from overtightening and maintaining coolant flow, thereby extending the lifespan of the cable and connected components while ensuring safety and reliability.
Implementation Method 1
a shape of the first clamping piece and the second clamping piece includes a curved portion that forces the charging cable of the electric vehicle charging station to exit the electric vehicle charging station at a predetermined exit angle
Implementation Method 2
Cable jacket grip is achieved by grip length with bends to increase frictional forces
Implementation Method 3
The charging cable may be a liquid cooled cable where liquid (e.g., propylene glycol, water, or other coolant) flows through the cable (such as through a flexible tube within the cable) that cools the cable (including the set of charging wires) during use
Data Source
AI summary
A cable clamp for a charging cable of an electric vehicle charging station. The cable clamp includes a first clamping piece and a second clamping piece that is complementary to the first clamping piece. The first clamping piece and the second clamping piece are adapted to be secured together and adapted to grip the charging cable of the electric vehicle charging station that passes through the first clamping piece and the second clamping piece. The shape of the first clamping piece and the second clamping piece includes a curved portion that forces the charging cable of the electric vehicle charging station to exit the electric vehicle charging station at a predetermined exit angle.