Tethered EV Disconnection Assembly for Cable Tension Relief
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Solution Overview
Problem
Existing power supply systems for vehicles face issues with cable tension leading to unnecessary power interruptions, cable damage, and safety hazards due to sudden tension forces, especially when the vehicle operates close to the cable's limit, and residual motion after power interruption can strain the cable to breaking point.
Innovation Solution
A power cable assembly with an anchor and disconnection switch that supports a slack cable portion, allowing detachment of the anchor under a threshold tension force, triggering the switch to interrupt power, and requiring manual reattachment to restore power, with a control system to ensure safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the power supply is disconnected when the cable is under excessive tension, then the cable is protected from damage, but the machine undergoes residual motion that can further strain the cable to breaking point
Solution Approach 1:
The anchor is detachably connected to the mount before tension occurs, positioned to provide preliminary support for the cable. When excessive tension is detected, the anchor automatically detaches, having already provided its protective function. This preliminary positioning allows the system to respond to tension without requiring complex real-time adjustment mechanisms.
Solution Approach 2:
The anchor acts as an intermediary element between the cable and the mount. It provides a detachable connection point that mediates the force transmission, allowing the cable to be supported under normal conditions but automatically disconnect when tension exceeds safe levels, protecting both the cable and the mount from damage.
2Strength
If a mechanical joint is used to retain the plug in the socket to resist detachment under load, then the connection is stronger, but the joint may resist disconnection and a suddenly applied tension force could damage the cable before disconnection occurs
Solution Approach 1:
The connection system is segmented into two distinct functions: the permanent mechanical joint between mount and vehicle, and the detachable anchor-cable connection. This segmentation allows the permanent joint to provide strong retention while the detachable anchor provides controlled disconnection capability, resolving the conflict between connection strength and disconnection ease.
Solution Approach 2:
The anchor connection transitions from a static permanent joint to a dynamic detachable connection. The anchor can be easily attached and detached from the mount, providing operational flexibility. The detachable nature allows quick repositioning and replacement, making the system adaptable to different operational requirements while maintaining strong connection when engaged.
Data Source
AI summary
An electric vehicle is supplied with power from a power supply via a cable suspended from an anchor. The anchor is attached to a mount on the vehicle and detachable from the mount by tension in the first portion of the cable between the anchor and the power supply. A second portion of the cable between the anchor and the vehicle remains slack in the attached position of the anchor, and extends on detachment of the anchor to relieve tension in the first portion of the cable. A disconnection switch is operable by detachment of the anchor to interrupt the power supply from the cable to the vehicle.