Swing Arm Selection Guide for EV Charging Stations

BESSUN · ENGINEERING GUIDE

How do you select the right Swing Arm for an EV charger?

Start with the weight and diameter of the cable section to be supported, then check cable length, outlet position, mounting height, working range and rotation clearance. Cable length alone does not determine the model.

At BESSUN, we frequently receive questions such as: “My charging cable is 7 m long; which model should I choose?” This Swing Arm selection guide explains how to assess the complete installation, using practical cable-routing examples and the BSM-SA model range.

For a comparison of different support mechanisms, read our EV Charging Cable Management Guide.

01 · Key Swing Arm Selection Criteria

Collect the following information before choosing an Swing Arm, connection and cable clamp as a matched assembly.

Cable length and routing: Record total charging cable length and the route from the charger outlet through the support point to the vehicle. Charging cable used in vertical routing is not available as horizontal reach.
Supported weight: Identify the charging cable section carried by the Swing Arm and the connector load transferred to it. Include movement and handling forces; do not select from total cable length or a static max load value alone.
Cable diameter and bend radius: Match the clamp to the actual outside diameter and tolerance. Respect the cable supplier’s minimum bend radius throughout movement and storage.
Charger outlet and mounting height: Record top, middle or bottom outlet position, mounting height above ground and available structural support. Check the mounting structure against the selected assembly and operating loads.
Working range: Map near and far vehicle inlet positions, parking variation, required cable slack and the return/storage position. Swing Arm length and total cable length are not the same as usable charging reach.
Rotation and clearance: Confirm the main-arm and secondary-joint angles for the exact configuration, including left/right orientation and stops. Check the full swept area for contact with the charger, vehicles and adjacent equipment.

02 · Charging Cable Length and Outlet Position: Practical Examples

The following length bands are starting points for layout review, not guaranteed model compatibility or reach limits. The sketches illustrate outlet positions and cable routing. Validate the selected configuration with the actual cable.

Cable Length up to 5 m

Cables up to 5 m can offer flexibility in the installation layout, but a short cable does not automatically suit every Swing Arm.

Models to evaluate: BSM-SA1, SA2, SA3 and SA4 have different structures and load ratings. Review the Swing Arm product range against the actual supported load and mounting space.
Outlet position: Top, middle and bottom outlets require different routing. Check how much cable remains available to reach the vehicle after passing through the support point.
Validation: Confirm clamp fit, bend radius and clearance at both the nearest and furthest charging positions.

Charging cable outlet: Top

Charging cable outlet: Middle

Cable Length 5–7 m

For cables between 5 and 7 m, outlet position and support-point height become especially important, alongside cable weight and required reach.

Middle or top outlet: BSM-SA1–SA4 may be candidates where their working loads, connection systems and movement envelopes suit the installation.
Bottom outlet: Evaluate BSM-SA5 when an integrated cable retractor could improve the routing and cable movement. Check usable travel and return force with the actual cable.
Check the complete path: Allow enough slack for vehicle connection without excessive ground contact, tight bends or interference during return.

Cable Length 7–10 m

Longer cables require a project-specific review of supported weight, available movement and ground clearance.

Around 7 m: BSM-SA5 with an integrated cable retractor is an option to evaluate, not an automatic choice based on length.
Approaching 10 m: A cable may still touch the ground, depending on its weight, routing, mounting height and vehicle position. Do not assume full suspension or 10 m of usable reach.
Before selection: Verify the retractor’s force and usable stroke for the supplied configuration, then test deployment, connection and return over the full working area.

Charging cable outlet: Bottom

When to consider overhead support: If a Swing Arm cannot meet the required reach or ground-clearance objective, assess an overhead arrangement. Full suspension still depends on structural support, cable routing and movement validation; it is not guaranteed by an overhead mounting position alone.

03 · BSM-SA1–SA5 Model Comparison

Compare the mechanical configuration first, then verify the load, connection and installation drawing for your project. The summary below follows the current BESSUN Swing Arm product page; it does not replace a configuration-specific technical drawing.

Model	Configuration	Working load*	Connection / selection check
BSM-SA1	Standard Swing Arm	30 kg	Soft or hard; verify arm reach and mounting
BSM-SA2	Compact three-fold Swing Arm	15 kg	Soft or hard; verify folded space and joint clearance
BSM-SA3	Swing Arm with dedicated clamp system	30 kg	BSM-SA3-specific soft or hard connection and clamp
BSM-SA4	Swing Arm with integrated housing	30 kg	Soft or hard; verify housing fit and movement clearance
BSM-SA5	Swing Arm with integrated cable retractor	30 kg	Soft only; confirm retractor force and usable stroke

*Working loads are listed on the current BESSUN product page. Confirm the exact supplied configuration before ordering. Maximum load under defined test conditions is not the recommended working load.

04 · Validate the Installation Before Production

Review the drawing: Mark cable outlet, mounting height, support point, arm travel and vehicle inlet positions. Confirm structural capacity and the correct left/right configuration.
Fit the actual cable: Check clamp fit and cable protection, minimum bend radius and the selected soft or hard connection. Use BSM-SA3-specific components for the BSM-SA3 assembly.
Test the full movement: Check near/far reach, joint limits, adjacent-equipment clearance, ground contact and connector storage. Test both deployment and return.
Assess handling: Verify pull force and return behaviour with the actual cable and connector. Evaluate a buffer where return movement requires additional control.
Approve the configuration: Record the selected model, arm dimensions, connection, clamp, force settings and validation results before volume production.

05 · Frequently Asked Questions

Which Swing Arm should I use for a 7 m charging cable?

A 7 m cable does not identify one correct model. Review supported weight, diameter, outlet position, mounting height and required reach. BSM-SA5 is an option when integrated retraction suits the layout, subject to force, stroke and movement validation.

Will a Swing Arm keep the entire cable off the ground?

Not in every installation. Ground clearance depends on cable weight and stiffness, support height, routing and vehicle position. Validate the complete operating envelope; longer cables may retain some ground contact.

How do mounting height and rotation angle affect selection?

Mounting height changes vertical routing and the cable length available to reach the vehicle. Joint angles and stops define the arm’s movement envelope. Check actual charging positions and collision clearance using the exact model drawing.

What is the difference between working load and maximum load?

Working load is the recommended load for normal operating conditions of the specified configuration. Maximum load relates to defined test conditions and must not be used as the routine operating rating or as a guarantee for another arm length.

Can a Swing Arm be added to an existing EV charger?

It can be evaluated where suitable mounting and structural support are available. Confirm enclosure reinforcement, service access, cable routing and the full swept area before installation.

06 · Discuss Your Swing Arm Project

BESSUN is an OEM/ODM supplier of EV charging cable management solutions. Share your cable and charger information so we can assess a suitable Swing Arm configuration.

Please include: cable length, outside diameter and tolerance, supported cable weight, connector weight, minimum bend radius, charger drawing and outlet position, mounting height, required working range, rotation/clearance constraints, operating environment and expected quantity.

Discuss Your Project with BESSUN →