The correct way to store the charging cable of an electric vehicle charger

The storage of charging cables for electric vehicle chargers should take into account safety, cable protection and operational convenience. The following provides systematic suggestions from four aspects: storage principles, methods, tool selection and precautions:

First, storage principles

Avoid bending damage

The core of the charging cable is composed of multiple copper cores and an insulating layer. If the bending radius is too small for a long time (such as less than 5 times the wire diameter), it will cause the copper core to break and the insulating layer to crack, resulting in a short circuit or leakage.

Standard: The minimum bending radius of the cable should be ≥ five times the wire diameter (for example, for a cable with a wire diameter of 8mm, the minimum bending radius should be ≥40mm).

Prevent pulling

Suddenly pulling the cable while charging may cause the plug to loosen or the internal wire to break. Make sure there are no suspended force-bearing points on the cable after it is stored.

Isolate environmental risks

Avoid contact of the cables with high temperatures (such as in the engine compartment), sharp objects, oil stains or chemical corrosions to prevent the insulation layer from aging.

Second, recommend storage methods

Winding storage method

Step:

Fix one end: Insert the charger plug into the fixing slot of the storage box or fix it with Velcro straps.

Spiral winding: Wind the cable in a clockwise direction with a radius of ≥40mm, with an interval of 5-10mm between each turn.

Fix the other end: Use straps or storage box clips to secure the end of the wire to prevent it from coming apart.

Tools: You can choose a storage box with a spiral guide rail (such as the original Tesla storage box), or a self-made PVC winding frame.

Layer-by-layer suspension method

Scene: Suitable for fixed installation in garages or charging stations.

Step:

Install cable hooks with slots on the wall (with a spacing of ≥15cm).

Hang the cables in layers to avoid cross-squeezing.

Advantages: Reduce ground friction and extend the lifespan of cables.

Scroll-type storage

Tools: Electric or manual reel (such as industrial-grade cable reels).

Note:

Give priority to choosing a reel with an automatic locking function to prevent the cable from accidentally bouncing back.

The winding tension should be moderate to avoid excessive stretching.

Third, storage precautions

Avoid being entangled by "dead knots"

Dead knots can cause local stress concentration in the cable, making it prone to breakage after long-term use. The correct approach is to use the "8" winding method or spiral winding.

Temperature control

During the hot summer, avoid placing the stored cables in a sealed vehicle (where the temperature can reach over 60℃). They should be kept in a cool place.

Regular inspection

Check the appearance of the cable every three months:

Check for cracks or exposed copper wires (which need to be replaced immediately).

Check if the plug contacts are oxidized (they can be cleaned with alcohol swabs).

The insulation layer is elastic (normally it should be able to quickly return to its original state; if it hardens, it needs to be replaced).

Child and pet protection

After storage, keep the cables out of the reach of children and pets to prevent them from gnawing and causing electric leakage.

Fourth, warning cases of incorrect storage

Case 1: The user randomly crumpled the cable into a ball and stuffed it into the trunk, causing the outer skin of the cable to crack three months later and smoke to come out when charging.

Case 2: The charging station did not use a cable reel. The cable dragged on the ground and was run over by a vehicle, causing the internal copper core to break and resulting in a fire.

Summary

The core of proper storage of charging cables is to reduce physical damage and avoid environmental risks. It is recommended to give priority to choosing spiral winding boxes or wall hooks, combined with regular inspections, which can significantly extend the lifespan of the cables (usually up to more than 5 years). If the cable is damaged, it must be replaced immediately (for example, the replacement cost of Tesla's third-generation charging cable is about 800 to 1,200 yuan), to avoid losing more than you gain.