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Language
English (en)
Publication Date
Fall 2025
Document Type
Final Report
Embargo Date
1-9-2027
Problem Statement
The Extendable EV Charger project set out to make a robotic mast that could extend to 4-5 feet and retract to less than 8 inches while support level 2 charging. The customer is Explication Automation, LLC, a local startup whose mission is to address the dexterity challenges people with disabilities face with manual EV charging. The most important customer needs are that the design is compact 6-8 inches, extends 4-5 feet, supports level 2 charging, and withstands harsh weather conditions. After iterative design with an initial prototype, the final prototype was designed using a linear actuator to extend custom made aluminum scissor links, housed within modular PLA parts, and sliding drawer rails to facilitate smooth extension and retraction. The prototype was evaluated using the following prototype performances goals: device goes from fully retracted (≤ 8 in) to fully extended (4-5 ft) in the horizontal plane and back again in under 1 minute, device goes from fully retracted to fully extended in the horizontal plane with ≥ 1 kg mass attached to the end and an axial compressive end load of ≥ 2.25 lb, and the device weighs ≤ 5 lb. Our final prototype design was a strong attempt but fell short of meeting the performance goals. Future improvements include optimizing the modular geometry for higher moment of inertia to reduce deflection of the extended mast, minimizing weight by developing a lighter sliding rail system, and reducing initial force required for extension by optimizing scissor link geometry.
Class Name
Mechanical Engineering Design Project (MEMS 411)
Recommended Citation
Corbett, James; Durkovic, Ben; Li, Jeremy; and Cho, Kai, "MEMS 4110: Extendable EV Charger" (2025). Mechanical Engineering Design Project Class. 258.
https://openscholarship.wustl.edu/mems411/258
Comments
Embargo Period: 1 Year