Production process of liquid cooling charging gun

Abstract

The invention discloses a production process of a liquid cooling charging gun, and particularly relates to the technical field of production processes of liquid cooling charging guns. A signal terminal, a power terminal and a grounding terminal are covered, a charging gun main shell, an insertion core, a support, a gun shell upper cover and a gun shell upper handle rear cover are integrally formed by adopting an insulating material, a water-immersed copper type cooling cable is selected, an insertion terminal, the support and a liquid cooling cable are assembled in order, and a gun locking device is assembled in a standard mode. According to the production process of the liquid cooling charging gun, a good heat dissipation effect is achieved through a liquid cooling system, an electronic pump drives cooling liquid to accurately circulate in the system, heat of a liquid cooling cable and a charging connector is efficiently taken away, and the purposes that a small-sectional-area cable bears large current and the temperature rise is low are achieved; equipment faults and safety risks caused by overheating are effectively avoided, the reliability and durability of equipment are remarkably enhanced, the service life is prolonged, the maintenance cost is reduced, and a foundation is built for rapid and stable charging of new energy automobiles.

Description

Technical Field

[0001] The present invention relates to the technical field of production technology of liquid-cooled charging guns, and in particular to a production technology of liquid-cooled charging guns. Background Art

[0002] As the share of new energy vehicles in the market continues to rise, driving range and charging time have become two key factors restricting the development of new energy vehicles. As the driving range increases, the battery capacity will also increase accordingly, and the charging time will also increase. High-power fast charging technology has gradually become a key means to solve the bottleneck of driving range;

[0003] In particular, the application of high-power liquid-cooled charging technology can enable electric vehicles to quickly replenish energy in a short period of time and properly solve the heat dissipation problem during high-current and high-voltage charging. The production process of high-power liquid-cooled charging guns directly affects the performance and service life of the charging equipment, so researching and improving these processes is of great significance to promoting the development of the electric vehicle industry. Summary of the invention

[0004] The main purpose of the present invention is to provide a production process for a liquid-cooled charging gun, which can effectively solve the heat dissipation problem during high-voltage charging. The production process of a high-power liquid-cooled charging gun directly affects the performance and service life of the charging equipment.

[0005] To achieve the above object, the technical solution adopted by the present invention is:

[0006] A production process of a liquid-cooled charging gun, comprising the following steps:

[0007] S1. First, we select materials and manufacture wiring terminals accurately based on the difference in conductivity, including signal terminals, power terminals and ground terminals;

[0008] The main housing, plug core, bracket, upper cover and upper handle back cover of the charging gun are integrally formed using insulating materials, and mounting holes are precisely machined at key locations.

[0009] Use water-immersed copper cooling cables to construct a 1-in / 2-out cooling circuit, use FEP to create liquid cooling inlet and outlet pipes, and carefully process the cables, including precise cutting and stripping of the TPU outer wall and part of the insulation to expose the wires;

[0010] S2. Assemble the plug-in terminals, brackets and liquid-cooled cables in order, strictly crimp the plug-in terminals and wires, and test the tension and temperature rise according to national standards;

[0011] The power terminal and the liquid cooling inlet and outlet pipes are firmly connected by the flow channel adapter and equipped with a special locking nut;

[0012] The grounding terminal and the plug-in terminal are precisely assembled on the bracket by means of the annular anti-drop groove, and the sealing ring and the metal retaining spring are installed;

[0013] S3. Place the fully assembled terminals, brackets and cables accurately into the main housing and the plug core, use the mounting hole screws to tightly connect the bracket and the plug core, and the plug core and the gun housing body. A sealing ring is installed at the tail of the plug core, and the gun housing body and the plug core are reinforced with locking screws;

[0014] S4. Standardize the assembly of the gun lock device, accurately insert the electronic lock core wire into the electronic lock hole of the gun housing body for positioning and installation, and insert the micro switch lead wire into the corresponding hole for fixing;

[0015] Install the pre-prepared spring, hook, plug shaft, and latch clamp into the corresponding positions of the gun case in sequence and tighten with screws. The gun case cover is tightly locked with the gun case body by means of a buckle;

[0016] S5. Accurately assemble the cable waterproof plug between the tail of the gun housing and the liquid cooling cable, and tightly lock the wire locking device with the gun housing body with screws;

[0017] The liquid cooling outlet pipeline is firmly connected to the gun tail wire riveted adapter via a locking nut, and the gun tail wire riveted adapter is reliably connected to the tail terminal via threads.

[0018] Preferably, the liquid-cooling terminal includes a metal contact terminal and a fully insulated terminal, the metal contact terminal is used for a non-conductive medium, and the fully insulated terminal is used for a conductive medium.

[0019] Preferably, the cooling tube is made of FEP material, the hardness range of the FEP material is 60 to 220 Shore A, and the temperature resistance range of the FEP material is 85 to 100°C.

[0020] Preferably, the water-immersed copper conductor is braided with tinned copper wires after bundle twisting and re-twisting, and the braiding density ranges from 83% to 87%.

[0021] Preferably, the cable waterproof plug is assembled between the rear of the gun housing body and the liquid cooling cable, and screws are used to lock and connect the wire pressing locking device to the gun housing body.

[0022] Preferably, the liquid cooling outlet pipe is connected to the gun tail wire riveted adapter via a locking nut, and the gun tail wire riveted adapter is connected to the tail terminal via its own thread.

[0023] Preferably, the annular anti-slip groove of the bracket fits with the terminal assembly cylindrical surface.

[0024] Compared with the prior art, the present invention has the following beneficial effects:

[0025] 1. The present invention achieves good heat dissipation effect through the liquid cooling system. The electronic pump drives the coolant to circulate accurately in the system, efficiently taking away the heat of the liquid cooling cable and the charging connector, and achieving the goal of small cross-sectional area cables carrying large currents and low temperature rise. It not only improves the charging efficiency and shortens the charging time, but also ensures the stable and safe operation of the charging gun under high-power conditions, effectively avoids equipment failures and safety risks caused by overheating, significantly enhances equipment reliability and durability, prolongs service life, reduces maintenance costs, and lays a solid foundation for the fast and stable charging of new energy vehicles.

[0026] 2. The present invention adopts high-performance FEP material for the cooling pipe, which has the properties of pressure resistance, heat aging resistance, oil resistance, and acid and alkali resistance, so that its performance is stable and reliable in a complex and changeable working environment. Compared with traditional materials, FEP material has the advantages of -60 to 220 Shore A hardness and 85 to 100°C temperature resistance, which greatly improves the cable's ability to adapt to harsh working conditions, successfully resists erosion and damage from external factors, greatly extends the service life of liquid-cooled charging pile cables, reduces the manpower, material and time costs caused by frequent cable replacement, ensures the long-term stable operation of charging infrastructure, and improves overall economic benefits and operational efficiency.

[0027] 3. The innovative assembly process of the present invention provides solid support for the stable performance of the charging gun. All components are made of excellent materials and precisely processed. For example, the manufacturing of terminals and shells strictly follows standards to ensure quality from the source. The assembly process is closely linked and accurate. The crimping of terminals and wires is strictly inspected, the power terminals are tightly and reliably connected, the brackets and terminals are firmly and accurately assembled, and the parts of the gun body are tightly connected. The refined assembly ensures that the internal structure of the charging gun is compact, the electrical connection is stable, and the mechanical performance is reliable. It effectively reduces the increase in contact resistance, signal transmission interference and component loosening risks caused by poor assembly, comprehensively improves the performance consistency and stability of the charging gun, optimizes the charging experience, and provides stable and efficient technical guarantees for charging new energy vehicles. DETAILED DESCRIPTION

[0028] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below in conjunction with specific implementation methods.

[0029] Embodiment 1, a production process of a liquid-cooled charging gun, comprising the following steps:

[0030] S1. First, we select materials and manufacture wiring terminals accurately based on the difference in conductivity, including signal terminals, power terminals and ground terminals;

[0031] The main housing, plug core, bracket, upper cover and upper handle back cover of the charging gun are integrally formed using insulating materials, and mounting holes are precisely machined at key locations.

[0032] Use water-immersed copper cooling cables to construct a 1-in / 2-out cooling circuit, use FEP to create liquid cooling inlet and outlet pipes, and carefully process the cables, including precise cutting and stripping of the TPU outer wall and part of the insulation to expose the wires;

[0033] S2. Assemble the plug-in terminals, brackets and liquid-cooled cables in order, strictly crimp the plug-in terminals and wires, and test the tension and temperature rise according to national standards;

[0034] The power terminal and the liquid cooling inlet and outlet pipes are firmly connected by the flow channel adapter and equipped with a special locking nut;

[0035] The grounding terminal and the plug-in terminal are precisely assembled on the bracket by means of the annular anti-drop groove, and the sealing ring and the metal retaining spring are installed;

[0036] S3. Place the fully assembled terminals, brackets and cables accurately into the main housing and the plug core, use the mounting hole screws to tightly connect the bracket and the plug core, and the plug core and the gun housing body. A sealing ring is installed at the tail of the plug core, and the gun housing body and the plug core are reinforced with locking screws;

[0037] S4. Standardize the assembly of the gun lock device, accurately insert the electronic lock core wire into the electronic lock hole of the gun housing body for positioning and installation, and insert the micro switch lead wire into the corresponding hole for fixing;

[0038] Install the pre-prepared spring, hook, plug shaft, and latch clamp into the corresponding positions of the gun case in sequence and tighten with screws. The gun case cover is tightly locked with the gun case body by means of a buckle;

[0039] S5. Accurately assemble the cable waterproof plug between the tail of the gun housing and the liquid cooling cable, and tightly lock the wire locking device with the gun housing body with screws;

[0040] The liquid cooling outlet pipeline is firmly connected to the gun tail wire riveted adapter via a locking nut, and the gun tail wire riveted adapter is reliably connected to the tail terminal via threads.

[0041] The working principle of the high-power liquid-cooled charging gun is as follows:

[0042] The high-power liquid-cooled charging gun in this solution uses an electronic pump to drive the coolant circulation. The coolant flows through the liquid-cooled cable that carries large current and generates heat, absorbs the heat of the cable and the charging connector, and then flows back to the fuel tank. It is then pushed to the radiator through the electronic pump to dissipate heat, thereby achieving the effect of a small-section cable carrying large current and maintaining a low temperature rise, ensuring that the charging gun can work stably under high-power operation, greatly improving charging efficiency and safety, and effectively avoiding equipment damage and safety hazards caused by overheating.

[0043] Furthermore, the liquid-cooling terminal includes a metal contact terminal and a fully insulated terminal, the metal contact terminal is used for a non-conductive medium, and the fully insulated terminal is used for a conductive medium.

[0044] Furthermore, the cooling pipe is made of FEP material, the hardness range of the FEP material is 60 to 220 Shore A, and the temperature resistance range of the FEP material is 85 to 100°C.

[0045] Furthermore, the water-immersed copper conductor is braided with tinned copper wires after being bundle-twisted and re-twisted, and the braiding density ranges from 83% to 87%.

[0046] The liquid cooling system component structure is designed as follows:

[0047] (1) Liquid-cooled terminal structure:

[0048] The structure of the liquid cooling terminal is crucial to the cooling efficiency. The diameter of the cooling pipe connection determines the unit flow rate of the coolant. The unit capacity of the cooling pipe at the connection terminal is larger than the liquid inlet pipe, which can reduce the coolant inflow pressure and prevent leakage at the connection. Specific liquid cooling terminals are adapted for different cooling media, and metal contact terminals are used for non-conductive media to ensure good heat conduction.

[0049] The conductive medium uses fully insulated terminals to eliminate the risk of short circuit caused by contact between the coolant and the terminals, improve system stability and safety, and optimize cooling effect and equipment reliability;

[0050] The hardness table of the materials used in the above is as follows:

[0051] Cooling pipe material Hardness / Shore A Temperature resistance grade / ℃ TPO 40～100 -40～125 TPE 0～100 -30～110 PA 50～100 -45～120 TPU 50～100 -30～120 FEP 85～100 -60～220

[0052] (2) Cooling pipe design:

[0053] The cooling pipe material is a key factor in determining the life of liquid-cooled charging pile cables. After a comprehensive evaluation of materials such as thermoplastic polyolefin (TPO), thermoplastic elastomer (TPE), polyamide (PA), thermoplastic polyurethane elastomer (TPU) and polyfluoroethylene propylene (FEP), FEP stands out for its excellent compression resistance, heat aging resistance, oil resistance, acid and alkali resistance. Its hardness is -60 to 220 (Shore A) and its temperature resistance is 85 to 100°C, which is far higher than other materials. It can adapt to complex working conditions, greatly extend the service life of the cable, reduce maintenance costs, and ensure the long-term and stable operation of the charging gun.

[0054] (3) Conductor design:

[0055] Liquid-cooled charging pile cables have strict requirements on conductor manufacturing process and cooling tube material selection due to the liquid cooling circulation system. They use 6 types of conductors in GB / T3956-2008 standard, such as "water-immersed copper" conductors, which are braided with tinned copper wires after bundle twisting and re-twisting. The braiding density is precisely controlled at 83% to 87%. At this density, the coolant flow rate and the conductor heat transfer efficiency are optimally balanced. 2Taking the 8mm diameter cable as an example, the cooling tube diameter is set to 12-14mm, and the coolant flow rate (≥6L·min), flow rate, cooling tube hardness, bursting pressure and outer diameter and other parameters are comprehensively considered to ensure that the conductor resistance is compliant, improve the cable current carrying and heat dissipation capacity, and enhance the overall performance of the charging gun.

[0056] Embodiment 2: This embodiment is based on embodiment 1 and is for achieving the purpose of the overall assembly process.

[0057] Specifically, the cable waterproof plug is assembled between the rear of the gun housing body and the liquid cooling cable, and the wire pressing locking device is locked and connected to the gun housing body using screws.

[0058] Furthermore, the liquid cooling outlet pipe is connected to the gun tail wire riveted adapter through a locking nut, and the gun tail wire riveted adapter is connected to the tail terminal through its own thread.

[0059] Furthermore, the annular anti-slip groove of the bracket fits with the terminal assembly cylindrical surface.

[0060] (1) Material selection and component manufacturing:

[0061] First, high-quality conductive materials are used to make signal terminals, power terminals and ground terminals; high-performance insulating materials are used to form the main housing, plug core, bracket, gun housing cover and gun housing upper handle back cover of the charging gun, and the mounting holes are precisely processed to ensure that each component has excellent mechanical strength and electrical insulation performance, providing a solid foundation for subsequent assembly and improving the overall quality and safety of the charging gun;

[0062] Secondly, the cooling cable uses water-immersed copper, and its cooling circuit is innovatively designed as 1 in 2 out. The liquid cooling inlet and outlet pipes are both made of FEP material. When preparing the cable, the TPU outer wall and part of the insulation skin are precisely cut and peeled off to accurately expose the wires, ensuring the electrical performance of the cable and the smooth circulation of the coolant, improving the heat dissipation efficiency and charging stability.

[0063] (2) Component assembly:

[0064] First, carefully assemble the plug-in terminals, brackets and liquid-cooled cables: accurately crimp the plug-in terminals and wires, and strictly test the tension and temperature rise according to GB / T20234 to ensure reliable connection and excellent electrical performance;

[0065] The power terminal and the liquid cooling inlet and outlet pipes are firmly connected through the flow channel adapter, and with the special locking nut, they are precisely assembled in accordance with the GB / T20234 and GB / T3956-2008 standards to ensure smooth coolant flow without leakage risk;

[0066] The grounding terminal and plug-in terminal are installed in the bracket's annular anti-drop groove, equipped with a sealing ring and a metal retaining spring to enhance the terminal's stability and sealing, and improve the charging gun's electrical safety and mechanical stability.

[0067] Secondly, the assembled terminals, brackets and cables are placed into the main housing and the plug in an orderly manner. The bracket and the plug, the plug and the gun body are precisely connected by the mounting hole screws. The sealing ring at the tail of the plug ensures the seal. The gun body and the plug are tightly fixed with locking screws to ensure that the internal structure is compact and stable, and the overall structural strength and protection performance of the charging gun are improved.

[0068] Then, accurately insert the electronic lock core wire into the electronic lock hole of the gun housing body for positioning and installation, and insert the micro switch lead wire into the corresponding hole to fix it;

[0069] The spring, hook, shaft, and latch clamp are installed into the corresponding positions of the gun housing in sequence and tightened with screws;

[0070] The upper cover of the gun case is tightly locked with the gun case body by means of a buckle, ensuring the reliable operation of the gun locking device, preventing the charging gun from accidentally separating, and improving the safety and convenience of use;

[0071] Finally, firmly connect the rear of the gun body, accurately assemble the cable waterproof plug between the rear of the gun body and the liquid cooling cable, and tightly lock the wire locking device with the gun body with screws;

[0072] The liquid cooling outlet pipe is firmly connected to the gun tail wire riveted adapter through a locking nut, and the gun tail wire riveted adapter is reliably connected to the tail terminal with threads, ensuring a stable and waterproof seal at the tail, thereby ensuring the overall reliable performance of the charging gun.

[0073] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A production process for a liquid-cooled charging gun, characterized in that: The following steps are involved: S1. First, we select materials and manufacture wiring terminals accurately based on the difference in conductivity, including signal terminals, power terminals and ground terminals; The main housing, plug core, bracket, upper cover and upper handle back cover of the charging gun are integrally formed using insulating materials, and mounting holes are precisely machined at key locations. Use water-immersed copper cooling cables to construct a 1-in / 2-out cooling circuit, use FEP to create liquid cooling inlet and outlet pipes, and carefully process the cables, including precise cutting and stripping of the TPU outer wall and part of the insulation to expose the wires; S2. Assemble the plug-in terminals, brackets and liquid-cooled cables in order, strictly crimp the plug-in terminals and wires, and test the tension and temperature rise according to national standards; The power terminal and the liquid cooling inlet and outlet pipes are firmly connected by the flow channel adapter and equipped with a special locking nut; The grounding terminal and the plug-in terminal are precisely assembled on the bracket by means of the annular anti-drop groove, and the sealing ring and the metal retaining spring are installed; S3. Place the fully assembled terminals, brackets and cables accurately into the main housing and the plug core, use the mounting hole screws to tightly connect the bracket and the plug core, and the plug core and the gun housing body. A sealing ring is installed at the tail of the plug core, and the gun housing body and the plug core are reinforced with locking screws; S4. Standardize the assembly of the gun lock device, accurately insert the electronic lock core wire into the electronic lock hole of the gun housing body for positioning and installation, and insert the micro switch lead wire into the corresponding hole for fixing; Install the pre-prepared spring, hook, plug shaft, and latch clamp into the corresponding positions of the gun case in sequence and tighten with screws. The gun case cover is tightly locked with the gun case body by means of a buckle; S5. Accurately assemble the cable waterproof plug between the tail of the gun housing and the liquid cooling cable, and tightly lock the wire locking device with the gun housing body with screws; The liquid cooling outlet pipeline is firmly connected to the gun tail wire riveted adapter via a locking nut, and the gun tail wire riveted adapter is reliably connected to the tail terminal via threads.

2. The production process of a liquid-cooled charging gun according to claim 1, characterized in that: The liquid-cooling terminal includes a metal contact terminal and a fully insulated terminal. The metal contact terminal is used for non-conductive media, and the fully insulated terminal is used for conductive media.

3. The production process of a liquid-cooled charging gun according to claim 1, characterized in that: The cooling pipe is made of FEP material, the hardness range of the FEP material is 60-220 Shore A, and the temperature resistance range of the FEP material is 85-100°C.

4. The production process of a liquid-cooled charging gun according to claim 1, characterized in that: The water-immersed copper conductor is braided with tinned copper wires after being bundle-twisted and re-twisted, and the braiding density ranges from 83% to 87%.

5. The production process of a liquid-cooled charging gun according to claim 1, characterized in that: The cable waterproof plug is assembled between the rear of the gun housing body and the liquid cooling cable, and screws are used to lock and connect the wire pressing locking device and the gun housing body.

6. The production process of a liquid-cooled charging gun according to claim 1, characterized in that: The liquid cooling outlet pipe is connected to the gun tail wire riveted adapter through a locking nut, and the gun tail wire riveted adapter is connected to the tail terminal through its own thread.

7. The production process of a liquid-cooled charging gun according to claim 1, characterized in that: The annular anti-slip groove of the bracket fits with the terminal assembly cylindrical surface.