Suspended Charging Cable System for Commercial Electric Vehicles
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Solution Overview
Problem
High power charging stations for commercial electric vehicles face challenges with heavy and stiff charging cables, making it difficult for individuals to handle and maneuver them for effective connection.
Innovation Solution
A charging system with a cable suspension post and arm that suspends the charging cable, allowing the connector to swing and rotate, and includes a recognition system and actuators for automatic alignment with the vehicle, reducing manual effort and improving cable management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high power charging cables are used to deliver 1 MW to 8 MW of electrical power, then the power delivery capability is improved, but the cable weight and stiffness increase significantly
Solution Approach 1:
The patent implements a dynamic cable management system where the cable transitions from a static heavy object to a dynamically controlled element. The cable is routed through guide pulleys and supported by tensioning mechanisms that allow it to move and position itself automatically, transforming the handling task from manual manipulation to a controlled dynamic system that adapts to connection requirements
2Power
If high power charging cables are used to deliver 1 MW to 8 MW of electrical power, then the power delivery capability is improved, but the cable stiffness increases making it difficult to maneuver
Solution Approach 1:
The system converts the stiff cable from a difficult-to-manage rigid element into a dynamically controllable component. Guide pulleys and tensioning devices work together to create a dynamic system where the cable can be positioned and oriented automatically, eliminating the need for manual bending and shaping that would be required with a purely manual system
Solution Approach 2:
The patent introduces intermediary elements (guide pulleys, tensioning mechanisms, and support structures) that mediate between the heavy stiff cable and the connection point. These intermediaries handle the mechanical stress and positioning requirements, allowing the cable to function effectively despite its inherent stiffness and weight
3Adaptability or versatility
If the charging cable length is increased to 3 m to 5 m to provide flexibility for positioning, then the positioning flexibility is improved, but the total cable weight increases to 56 kg to 375 kg
Solution Approach 1:
The system uses dynamic support mechanisms including guide pulleys and tensioning devices to manage the heavy cable. These mechanisms allow the cable to achieve and maintain positioning flexibility without requiring the entire cable mass to be manually manipulated, as the support system actively maintains the cable in the required position
Data Source
AI summary
A system for charging commercial electric vehicles, including buses and trucks. The system can include a charging station that outputs a supply of relatively high voltage electrical power, and a cable suspension post having a support post and a suspension arm. The suspension arm can be suspended away from the support post at a vertical height that is higher than the height of typical commercial vehicles. At least a portion of a charging cable is electrically coupled to the charging station and suspended from the suspension arm. A charging connector can be free-hanging from the suspended portion of the charging cable, and therefore be swingingly displaceable into electrical engagement with a mating connector of the vehicle. The suspension arm can be rotatably displaced relative to the support post and/or another portion of the suspension arm such that a vertical height and/or other position of the suspended arm can be adjusted.