High-power charging cable for charging new energy automobile and use method

Abstract

The invention relates to the technical field of cables, in particular to a high-power charging cable for charging a new energy automobile and a using method of the high-power charging cable. Connecting a high-power charging cable to the charging pile and the charging gun; and the charging gun is inserted into the charging port of the new energy automobile to start the charging pile to charge the new energy automobile. By optimizing the material and the structure of the conductor, the technology can support higher power-on current, so that the charging time is greatly shortened, the charging experience of a user is improved, the risk of damage to the wire core is effectively reduced by strengthening the protection measure of the wire core, using a high-strength insulating material, adding a shielding layer or a protection layer and the like, and the service life of the wire core is prolonged. And particularly, the core breaking problem of the control wire core is solved, so that the transmission performance and the charging safety of the cable are ensured. Therefore, the problem that a traditional high-power charging cable is short in service life is solved.

Description

Technical Field

[0001] The present invention relates to the field of cable technology, and in particular to a high-power charging cable for charging new energy vehicles and a use method thereof. Background Art

[0002] In recent years, with the rapid development of the new energy vehicle industry, the market demand for supporting new energy vehicles has also been increasing. However, due to the limited current (usually no more than 250A) of traditional DC charging cables, the charging time is long (more than 2 hours), which seriously affects the user's charging experience. In order to increase the charging speed, some manufacturers try to increase the current carrying capacity by increasing the conductor cross-section, but this method often leads to an increase in the outer diameter of the cable and a decrease in softness, which brings inconvenience to use and storage.

[0003] In addition, high-power charging cables are frequently bent, dragged, and wound during use, which can easily damage the core inside the cable, especially the control core, which is more prone to core breakage due to its slender structure. Core breakage not only affects the transmission performance of the cable, but may also cause safety hazards and pose a threat to the charging safety of new energy vehicles. Summary of the invention

[0004] The object of the present invention is to provide a high-power charging cable for charging new energy vehicles and a method of use, aiming to solve the problem of low service life of traditional high-power charging cables.

[0005] To achieve the above objectives, in a first aspect, the present invention provides a method for using a high-power charging cable for charging a new energy vehicle, comprising the following steps:

[0006] Prepare a semi-finished cable product using a ground wire core conductor, a power wire core conductor, a cooling tube, a signal wire core conductor, a control wire core conductor, and an auxiliary power wire core conductor;

[0007] The sheath is extruded from the semi-finished product by an extrusion process to obtain a high-power charging cable;

[0008] Connect the high-power charging cable to the charging pile and the charging gun;

[0009] Insert the charging gun into the charging port of the new energy vehicle and start the charging pile to charge the new energy vehicle.

[0010] Among them, in “preparing a semi-finished cable using a ground wire core conductor, a power wire core conductor, a cooling tube, a signal wire core conductor, a control wire core conductor and an auxiliary power wire core conductor”, the following steps are included:

[0011] Prepare ground wire core conductors, power wire core conductors, cooling tubes, signal wire core conductors, control wire core conductors and auxiliary power wire core conductors;

[0012] Conductors, cooling tubes and insulation layers are irradiated and cross-linked;

[0013] The signal wire cores, control wire cores and auxiliary power wire cores are twisted into cables to form their own cable groups;

[0014] The ground wire core, the signal wire core group, the control wire core group, the auxiliary power wire core group and the power wire core group are twisted together to obtain a semi-finished product.

[0015] Among them, the process of “irradiating and cross-linking each conductor, cooling tube and insulation layer” includes the following steps:

[0016] Put the ground wire core conductor, power wire core conductor, cooling tube, signal wire core conductor, control wire core conductor and auxiliary power wire core conductor into the extruder in sequence to extrude the insulation layer;

[0017] The ground wire core conductor, the power wire core conductor, the cooling tube, the signal wire core conductor, the control wire core conductor and the auxiliary power supply wire core conductor and the insulation layer are placed in the radiation cross-linking equipment for radiation cross-linking treatment.

[0018] Among them, "twisting the signal cores, control cores and auxiliary power cores into cables to form their own cable groups" includes:

[0019] The signal core, control core and auxiliary power core are placed in a twisting machine for twisting, and a shielding layer is added to form multiple cable groups.

[0020] Among them, “twisting the ground wire core, signal wire core group, control wire core group, auxiliary power wire core group and power wire core group to obtain a semi-finished product” includes: twisting the ground wire core, signal wire core group, control wire core group, auxiliary power wire core group and power wire core group and adding a protective layer to obtain a semi-finished product.

[0021] Among them, in “connecting the high-power charging cable to the charging pile and the charging gun”, the following steps are included:

[0022] Installing connectors at both ends of the high-power charging cable;

[0023] The high-power charging cable is connected to the charging pile and the charging gun through the connector and fixed.

[0024] In a second aspect, a high-power charging cable for charging a new energy vehicle is provided, which is used in the method for using the high-power charging cable for charging a new energy vehicle described in the first aspect.

[0025] A method for using a high-power charging cable for charging a new energy vehicle of the present invention comprises the following steps:

[0026] A cable semi-finished product is prepared using a ground core conductor, a power core conductor, a cooling tube, a signal core conductor, a control core conductor and an auxiliary power core conductor; an extrusion process is used to extrude a sheath from the semi-finished product to obtain a high-power charging cable; the high-power charging cable is connected to a charging pile and a charging gun; the charging gun is inserted into the charging port of a new energy vehicle to start the charging pile to charge the new energy vehicle. By optimizing the conductor material and structure, the present invention can support a higher current (far exceeding the 250A limit of traditional DC charging cables), thereby greatly shortening the charging time and improving the user's charging experience. By strengthening the protection measures for the core, using high-strength insulating materials, adding shielding layers or protective layers, etc., the risk of core damage is effectively reduced, especially the problem of broken cores of the control core, thereby ensuring the transmission performance and charging safety of the cable. This solves the problem of low service life of traditional high-power charging cables. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0028] Figure 1 The present invention provides a flow chart of a method for using a high-power charging cable for charging a new energy vehicle.

[0029] Figure 2 It is a flow chart for preparing a semi-finished cable using a ground wire core conductor, a power wire core conductor, a cooling tube, a signal wire core conductor, a control wire core conductor and an auxiliary power wire core conductor.

[0030] Figure 3 This is a flow chart of the radiation cross-linking treatment of each conductor, cooling tube and insulation layer.

[0031] Figure 4 It is a flow chart of connecting the high-power charging cable to the charging pile and the charging gun. DETAILED DESCRIPTION

[0032] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended to be used to explain the present invention, and should not be construed as limiting the present invention.

[0033] See also Figures 1 to 4In a first aspect, the present invention provides a method for using a high-power charging cable for charging a new energy vehicle, comprising the following steps:

[0034] S1 uses a ground wire core conductor, a power wire core conductor, a cooling tube, a signal wire core conductor, a control wire core conductor and an auxiliary power wire core conductor to prepare a semi-finished cable;

[0035] S11 prepares a ground wire core conductor, a power wire core conductor, a cooling tube, a signal wire core conductor, a control wire core conductor and an auxiliary power supply wire core conductor;

[0036] Specifically, according to the design requirements, the ground wire core conductor, power wire core conductor, cooling tube, signal wire core conductor, control wire core conductor and auxiliary power wire core conductor are prepared using high conductivity, corrosion-resistant copper or copper alloy materials. The cooling tube uses high temperature resistant, corrosion-resistant materials, stainless steel or polymer materials.

[0037] S12 performs radiation cross-linking treatment on each conductor, cooling tube and insulation layer;

[0038] S121 puts the ground wire core conductor, the power wire core conductor, the cooling tube, the signal wire core conductor, the control wire core conductor and the auxiliary power wire core conductor into the extruder in sequence to extrude the insulation layer;

[0039] Specifically, the ground wire core conductor, power wire core conductor, cooling tube, signal wire core conductor, control wire core conductor and auxiliary power wire core conductor are sequentially placed in an extruder, and the insulation layer is extruded by controlling the temperature and pressure. The insulation layer has good electrical insulation performance and mechanical strength, and is used to protect the internal conductor from the external environment. The insulation layer is made of polyolefin or cross-linked polyethylene.

[0040] S122 puts the ground wire core conductor, power wire core conductor, cooling tube, signal wire core conductor, control wire core conductor and auxiliary power wire core conductor and insulation layer into the radiation cross-linking equipment for radiation cross-linking treatment.

[0041] Specifically, the conductors and cooling tubes with insulation layers are placed in a radiation cross-linking device and subjected to radiation cross-linking treatment using high-energy radiation, which is used to increase the cross-linking degree of the insulation layer, enhance its heat resistance, chemical corrosion resistance and mechanical strength, and thus extend the service life of the cable.

[0042] S13 respectively twists the signal wire cores, the control wire cores and the auxiliary power wire cores into cables to form respective cable groups;

[0043] The signal core, control core and auxiliary power core are placed in a twisting machine for twisting, and a shielding layer is added to form multiple cable groups.

[0044] Specifically, the signal core, control core and auxiliary power core are placed in a twisting machine respectively and twisted according to a predetermined twisting pitch and twisting direction. During the twisting process, a shielding layer (copper foil or braided mesh) is added to effectively suppress electromagnetic interference and signal leakage, and improve the transmission performance and anti-interference ability of the cable. After the twisting is completed, multiple cable groups are formed.

[0045] S14 twists the ground wire core, the signal wire core group, the control wire core group, the auxiliary power wire core group and the power wire core group to obtain a semi-finished product.

[0046] The ground wire core, the signal wire core group, the control wire core group, the auxiliary power wire core group and the power wire core group are twisted and a protective layer is added to obtain a semi-finished product.

[0047] Specifically, the ground wire core, signal wire core group, control wire core group, auxiliary power wire core group and power wire core group are twisted together to ensure that the position of each wire group in the cable is stable and evenly distributed. During the twisting process, a protective layer (polyvinyl chloride or polyethylene sheath) is added to protect the internal cables from external mechanical damage and harsh environment. After the twisting is completed, a semi-finished cable is obtained.

[0048] S2 uses an extrusion process to extrude the sheath from the semi-finished product to obtain a high-power charging cable;

[0049] Specifically, the sheath material is evenly extruded and wrapped around the outer surface of the semi-finished cable by an extrusion process. The sheath has good wear resistance, weather resistance and fire resistance, ensuring the safety and reliability of the cable during long-term use. After extrusion, a high-power charging cable is obtained.

[0050] Conducting appearance, size, electrical performance, mechanical performance, and flame retardant performance testing and evaluation on the high-power charging cable;

[0051] The appearance inspection includes checking whether the sheath is complete, without damage, cracks or missing parts; whether the surface of the sheath is smooth and round, without bubbles, inclusions, sand holes, etc.; confirming whether the color of the sheath is uniform and consistent, without color difference or spots.

[0052] The dimensional inspection includes measuring the thickness of the sheath to ensure that it meets the nominal thickness specified in the process; measuring the outer diameter of the cable to ensure that it is within the allowable error range; checking the eccentricity of the cable, that is, the unevenness between the sheath and the cable core, to ensure that it is within the specified range.

[0053] The electrical performance test includes: using an insulation resistance tester to measure the insulation resistance of the cable to ensure that it meets the requirements of relevant standards; measuring the DC resistance of the cable, calculating it according to the resistance law, and judging whether it meets the standards; and conducting a voltage withstand test on the cable to check whether it will have electrical breakdown under a certain voltage.

[0054] The mechanical property test includes: testing the tensile strength of the cable to ensure that it can withstand a certain external force without being damaged; measuring the elongation of the cable before breaking to evaluate its elasticity and toughness; and performing a bending test on the cable to check whether cracks or breaks will occur during the bending process.

[0055] The flame retardant performance test includes: conducting a combustion test on the cable to observe parameters such as its burning speed, smoke volume and toxicity to ensure that it meets the flame retardant performance requirements; measuring the mass loss of the cable under high temperature conditions to evaluate its thermal stability and aging resistance.

[0056] The evaluation includes: Summarizing and analyzing the results of the above tests to evaluate the overall quality of the cable. The cable is judged to be qualified. If the cable meets all requirements, it is judged as a qualified product; if not, it is reworked or scrapped.

[0057] S3 connects the high-power charging cable to the charging pile and the charging gun;

[0058] S31 installs connectors at both ends of the high-power charging cable;

[0059] Specifically, special connectors are installed at both ends of the high-power charging cable. The connectors have good electrical contact performance and mechanical connection strength to ensure reliable connection between the cable and the charging pile and charging gun. At the same time, the connectors also have waterproof and dustproof protection functions to adapt to various harsh usage environments.

[0060] S32 connects the high-power charging cable to the charging pile and the charging gun through the connector and fixes them.

[0061] Specifically, the high-power charging cable is connected to the charging pile and the charging gun through the connector, and fixed with a dedicated fixing device to ensure that the connection is firm to prevent loosening or falling off due to vibration or external force during use.

[0062] S4 inserts the charging gun into the charging port of the new energy vehicle and starts the charging pile to charge the new energy vehicle.

[0063] Specifically, insert the charging gun into the charging port of the new energy vehicle and start the charging process according to the operating instructions of the charging pile. During the charging process, monitor parameters such as charging current, voltage and temperature to ensure the safety and stability of the charging process. After charging is completed, disconnect and remove the charging gun according to the operating procedures.

[0064] The present invention provides a high-power charging cable for charging new energy vehicles and a method of use thereof, which has the following beneficial effects:

[0065] 1. The high-power charging cable and use method for charging new energy vehicles provided by the present invention significantly improve the service life of the cable: The present invention adopts radiation cross-linking treatment technology to strengthen the conductors, cooling tubes and insulation layers, significantly improving the wear resistance, corrosion resistance and aging resistance of the cable, thereby greatly extending the service life of the cable. At the same time, by adding a shielding layer around the signal core, control core and auxiliary power core, and adding a protective layer to the semi-finished cable after twisting, the cable's anti-bending, anti-dragging and anti-winding capabilities are further enhanced, effectively reducing the core damage caused by frequent operation, especially the problem of broken cores of the control core, thereby further improving the service life of the cable.

[0066] 2. The present invention provides a high-power charging cable for new energy vehicles and a method of use thereof. The cable structure is optimized and durability is improved: The present invention fully considers various stress factors during use in the cable design. Through reasonable conductor cross-section selection, insulation layer thickness design and twisted structure optimization, the cable has good softness and durability while maintaining high current carrying capacity. In particular, the addition of the cooling tube not only helps to dissipate heat, but also can alleviate the internal stress of the cable during bending and dragging to a certain extent, further improving the durability of the cable.

[0067] 3. The high-power charging cable and use method for new energy vehicle charging provided by the present invention simplifies the installation and maintenance process: The high-power charging cable of the present invention is equipped with special connectors at both ends, which is convenient for users to quickly and easily connect the cable to the charging pile and charging gun without complicated installation steps or tools. At the same time, since the service life of the cable has been significantly improved, users can greatly reduce the frequency of replacing the cable during use, thereby reducing maintenance costs and time.

[0068] 4. The high-power charging cable and use method for new energy vehicle charging provided by the present invention ensure charging safety and user experience: The high-power charging cable of the present invention not only has high current carrying capacity and long service life, but also ensures safety and stability during charging through multiple protection measures (shielding layer, protective layer, etc.). This helps to improve the user's charging experience and reduce the inconvenience and loss caused by charging failures or safety issues.

[0069] The above disclosure is only a preferred embodiment of a high-power charging cable for charging new energy vehicles and a method of use of the present invention. Of course, this cannot be used to limit the scope of rights of the present invention. Ordinary technicians in this field can understand that all or part of the processes of the above embodiments are implemented, and equivalent changes made according to the claims of the present invention still fall within the scope of the invention.

Claims

1. A method for using a high-power charging cable for charging a new energy vehicle, characterized in that: The following steps are involved: Prepare a semi-finished cable product using a ground wire core conductor, a power wire core conductor, a cooling tube, a signal wire core conductor, a control wire core conductor, and an auxiliary power wire core conductor; The sheath is extruded from the semi-finished product by an extrusion process to obtain a high-power charging cable; Connect the high-power charging cable to the charging pile and the charging gun; Insert the charging gun into the charging port of the new energy vehicle and start the charging pile to charge the new energy vehicle.

2. The method for using the high-power charging cable for charging a new energy vehicle as claimed in claim 1, characterized in that: In "preparing a semi-finished cable product using a ground core conductor, a power core conductor, a cooling tube, a signal core conductor, a control core conductor and an auxiliary power core conductor", the following steps are included: Prepare ground wire core conductors, power wire core conductors, cooling tubes, signal wire core conductors, control wire core conductors and auxiliary power wire core conductors; Conductors, cooling tubes and insulation layers are irradiated and cross-linked; The signal wire cores, control wire cores and auxiliary power wire cores are twisted into cables to form their own cable groups; The ground wire core, the signal wire core group, the control wire core group, the auxiliary power wire core group and the power wire core group are twisted together to obtain a semi-finished product.

3. The method for using the high-power charging cable for charging a new energy vehicle as claimed in claim 2, characterized in that: In "irradiating and cross-linking each conductor, cooling tube and insulation layer", the following steps are included: Put the ground wire core conductor, power wire core conductor, cooling tube, signal wire core conductor, control wire core conductor and auxiliary power wire core conductor into the extruder in sequence to extrude the insulation layer; The ground wire core conductor, the power wire core conductor, the cooling tube, the signal wire core conductor, the control wire core conductor and the auxiliary power supply wire core conductor and the insulation layer are placed in the radiation cross-linking equipment for radiation cross-linking treatment.

4. The method for using the high-power charging cable for charging a new energy vehicle as claimed in claim 2, characterized in that: The step of "twisting the signal cores, control cores and auxiliary power cores into cables to form respective cable groups" includes: placing the signal cores, control cores and auxiliary power cores into twisting machines to twist them respectively, and adding shielding layers to form a plurality of cable groups.

5. The method for using the high-power charging cable for charging a new energy vehicle as claimed in claim 2, characterized in that: The step of "twisting the ground wire core, the signal wire core group, the control wire core group, the auxiliary power wire core group and the power wire core group to obtain a semi-finished product" includes: twisting the ground wire core, the signal wire core group, the control wire core group, the auxiliary power wire core group and the power wire core group and adding a protective layer to obtain a semi-finished product.

6. The method for using the high-power charging cable for charging a new energy vehicle as claimed in claim 1, characterized in that: In "connecting the high-power charging cable to the charging pile and the charging gun", the following steps are included: Installing connectors at both ends of the high-power charging cable; The high-power charging cable is connected to the charging pile and the charging gun through the connector and fixed.

7. A high-power charging cable for new energy vehicles, characterized in that: A method for using the high-power charging cable for charging new energy vehicles as described in any one of claims 1-6.

Images