U-Shaped EV Charging Cable Routing for Overhead Plug Protection
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Solution Overview
Problem
Charging cables for electric vehicles are prone to being run over by vehicles, exposed to moisture, and require easy accessibility and safe, compact storage when not in use.
Innovation Solution
A cable routing system with a U-shaped charging cable guided by a guide device, featuring a deflection unit that moves along guide rails, supported by cable carriers and a linear drive system, allowing the charging plug to be suspended and automatically lowered or raised, with a spring mechanism for easy handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the charging cable is routed horizontally next to the vehicle, then the charging plug is easily accessible, but the cable is exposed to being run over by the vehicle and damaged by moisture
Solution Approach 1:
The charging cable routing system transitions from a horizontal ground-level arrangement to a vertical ceiling-mounted arrangement. The cable is guided through a vertical deflection station that directs it downward to the vehicle charging point, eliminating exposure to vehicle traffic and moisture while maintaining accessibility through controlled deployment.
Solution Approach 2:
The charging plug and cable routing are extracted from the ground level and relocated to the ceiling area. This spatial separation removes the cable from harmful environments (vehicle traffic, moisture) while the plug remains accessible through vertical guidance to the vehicle charging point.
2Ease of operation
If the charging cable is made longer to reach the vehicle, then the charging plug is more accessible, but the cable requires more space for routing and storage
Solution Approach 1:
The cable routing utilizes the vertical dimension by guiding the cable downward from the ceiling through a vertical deflection station. This vertical deployment allows the cable to reach the vehicle without requiring excessive horizontal space, and the U-shaped routing with parallel legs minimizes the overall volume occupied by the cable system.
Solution Approach 2:
The deflection unit is designed to be movable along guide rails, allowing dynamic adjustment of the cable routing path. This enables the system to adapt to different vehicle positions and cable lengths, optimizing space utilization while maintaining accessibility.
3Reliability
If the deflection unit is made larger to handle thicker charging cables, then the cable can be better supported, but the space required for the deflection unit increases
Solution Approach 1:
The deflection unit is designed as a movable component that can be positioned along the guide rails according to the specific cable thickness and support requirements. This dynamic positioning allows the same deflection unit structure to handle various cable sizes without requiring multiple fixed-size units, optimizing space utilization while maintaining reliable support.
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 system ensures the charging plug is protected from collisions and moisture, easily accessible, and compactly stored, while minimizing space requirements and installation effort.
Implementation Method 1
with a spring mechanism for easy handling
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a cable guide system 1 for charging an electric vehicle, comprising a charging cable 2 with a charging plug 3 at its end, wherein the charging cable 2 is guided in a U-shaped manner in its course from a connection end to its end with the charging plug 3 in a guide device 4, so that the U-shaped charging cable 2 has two legs 8, 9 running next to one another or one above the other, wherein the end of the charging cable 2 carrying the charging plug 3 is deflected downwards in a stationary vertical deflection station 11, so that the charging plug 3 is arranged suspended below the vertical deflection station 11, wherein the guide device 4 has a deflection unit 16 for the U-shaped deflection,which is displaceable in a longitudinal direction of the guide device 4 and wherein the charging cable 2 is carried and guided by several cable carriers 24 between its connection end and the deflection unit 16 and between the deflection unit 16 and the vertical deflection station 11.