Hollow Telescoping Actuator With Pulley Wire Routing

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Solution Overview

Problem

Existing automated charging solutions for electric vehicles are bulky, expensive, and complex, often requiring significant structural modifications and are unable to perform level 3 "rapid" charging, limiting their widespread adoption.

Innovation Solution

A telescoping actuator with a hollow telescoping assembly and pulley system that extends and retracts without occupying its interior, allowing for the automatic and intelligent establishment of an electrical connection between a vehicle and a charging station, using a DC motor and conductive materials for efficient power delivery.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If a robotic arm is used for automated charging, then charging automation is achieved, but the system becomes bulky and obstructs pathways

Engineering Contradiction:

Improvecharging automationVSAvoidsystem bulk

Core Design Contradiction:

Extent of automationVSVolume of moving object

Solution Approach 1:

The charging system is divided into separate functional components: a fixed base unit housing the motor and control systems, and a telescoping assembly that extends only when needed for charging. This segmentation allows the automated charging function to be achieved while keeping the stationary structure compact and non-obstructive.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The telescoping assembly transitions from a static structure to a dynamic one, extending and retracting based on charging needs. The assembly remains retracted during normal vehicle passage, eliminating obstruction, and extends only when a vehicle requires charging, thus achieving automation without permanent bulk.

Inventive Principle:

Principle #15Dynamics

2Ease of operation

If induction charging is used, then wireless charging is achieved, but significant structural investments are required

Engineering Contradiction:

Improvewireless chargingVSAvoidstructural modifications

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces complex inductive charging systems with a simplified mechanical connection approach. Instead of embedding inductive plates in concrete or asphalt, the system uses a motor-driven telescoping assembly with direct electrical contacts, eliminating the need for significant structural modifications to the ground or infrastructure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If the telescoping assembly is solid, then structural strength is maintained, but wires cannot be routed through it

Engineering Contradiction:

Improvestructural strengthVSAvoidwire routing

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The telescoping assembly uses nested hollow segments that slide within each other, creating internal channels through which wires and cables can be routed. This nested hollow structure maintains structural strength through its tubular geometry while providing continuous pathways for electrical connections throughout the extending and retracting mechanism.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Ease of operation

If the wire is routed through the hollow interior of the telescoping assembly, then the assembly can extend and retract, but the wire occupies space needed for other components

Engineering Contradiction:

Improveextension and retractionVSAvoidhollow interior space

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The wire routing strategy transitions from occupying the central hollow interior space to running along the outer circumference of the telescoping segments. By routing the wire around the external perimeter rather than through the center, the hollow interior remains fully available for other components while the wire still follows the extension and retraction motion.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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

Enables efficient and cost-effective automatic charging without obstructing pathways, capable of performing level 3 rapid charging, thus overcoming the limitations of existing solutions.

Implementation Method 1

The motor may be a DC motor

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

The telescoping actuator may also include a pulley system that enables the telescoping assembly to be extended and retracted

Methodology Applied

Scientific EffectMechanical advantage: Mechanical Advantage

Implementation Method 3

using a DC motor and conductive materials for efficient power delivery

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11254230B1Telescoping actuator

Publication Date: 2022.02.22 MOD AL GROUP INC

AI summary

A telescoping actuator may be used with a charging station or other solution. The telescoping actuator can include a telescoping assembly that is hollow to thereby facilitate running wires or cables through the telescoping assembly. The telescoping actuator may also include a pulley system that enables the telescoping assembly to be extended and retracted without unduly occupying the hollow interior of the telescoping assembly.