Aluminum alloy charging cable assembly for light commercial vehicle

Abstract

The invention discloses an aluminum alloy charging cable assembly for a light commercial vehicle. The aluminum alloy charging cable assembly comprises a direct current charging socket, a grounding terminal, a battery pack charging interface plug-in, two main power cables and a grounding cable, a conductor of the main power supply cable is made of an aluminum alloy material, and two ends of the conductor are respectively connected with copper terminals in the direct current charging socket and the battery pack charging interface plug-in through ultrasonic welding; a conductor of the grounding cable is made of a copper material, and two ends of the conductor are respectively connected with the direct current charging socket and the grounding terminal. Compared with a traditional copper charging cable assembly, the cable assembly has the advantages that the weight of the cable assembly can be reduced by more than 40%, the vehicle body load of a light commercial vehicle is effectively reduced, the energy consumption of vehicle running is directly reduced due to the light weight of the cable assembly, and the endurance mileage of the whole vehicle is effectively increased. From the perspective of raw materials, the material cost of the cable assembly can be directly reduced; from the perspective of the whole life cycle, the vehicle production and subsequent operation cost is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of automobiles, in particular to an aluminum alloy charging cable assembly for light commercial vehicles. BACKGROUND

[0002] With the rapid development of the automobile industry towards new energy, the electric trend of light commercial vehicles is also increasingly evident. For new energy light commercial vehicles, reducing vehicle weight, reducing energy consumption, improving range and controlling cost are important development goals.

[0003] The existing new energy light commercial vehicles generally use copper charging cable assemblies. Due to the high density of copper material (about 8.96 g / cm³), the weight of the charging cable assembly usually accounts for more than 35% of the weight of the vehicle electrical system. The weight of a single set of charging cable assembly for some models exceeds 15 kg. In the case of high-power charging demand, the conductor cross-sectional area needs to be further increased (such as 400A or more current requiring a copper charging cable of 95mm²), resulting in a high overall weight of the cable assembly, directly increasing the load on the vehicle body and reducing the range. In addition, it also has a negative impact on braking and handling performance. At the same time, China's copper resources are limited and the price fluctuates greatly. The cost of the cable usually accounts for more than 60% of the total cost of the assembly, resulting in a significant increase in the material cost and cost control difficulty of the copper charging cable assembly, thereby directly forcing the new energy vehicle industry to accelerate technological innovation. SUMMARY

[0004] The technical problem to be solved by the present application is to provide an aluminum alloy charging cable assembly for light commercial vehicles, which reduces the weight of the vehicle body, reduces energy consumption, improves the range and controls the cost under the premise of ensuring the same electrical conductivity, has universality and is suitable for new energy light commercial vehicles with high-power charging, vehicle weight reduction and cost reduction requirements.

[0005] The technical problem to be solved by the present application is solved by the following technical solution: An aluminum alloy charging cable assembly for light commercial vehicles, comprising a direct current charging socket, a grounding terminal, a battery pack charging interface plug-in, two main power cables and one grounding cable; the conductor of the main power cable is made of aluminum alloy material, and the two ends thereof are connected to the copper terminals in the direct current charging socket and the battery pack charging interface plug-in through ultrasonic welding respectively; the conductor of the grounding cable is made of copper material, and the two ends thereof are connected to the direct current charging socket and the grounding terminal respectively.

[0006] Preferably, in the above technical solution, the aluminum alloy conductor of the main power cable and the copper terminal are wrapped with a corrosion-resistant sealing structure to isolate the medium.

[0007] Preferably, the anti-corrosion sealing structure comprises a heat shrink tube and sealing glue filled between the heat shrink tube and the welding position.

[0008] Preferably, the conductor cross-sectional area of the main power cable is a 120 mm² shielded silicone cable.

[0009] Preferably, the aluminum alloy material is an aluminum alloy of grade 6101.

[0010] Preferably, the ground cable is a yellow-green copper cable with a cross-sectional area of 25 mm², and the two ends are connected to the DC charging socket and the ground terminal through crimping, respectively.

[0011] Preferably, the main power cable is externally sleeved with a protective net, and the ground cable is externally sleeved with a black corrugated pipe.

[0012] Preferably, the DC charging socket is a DC01 DC charging socket, the ground terminal is a DC03 ground terminal, and the battery pack charging interface plug-in is a DC04 battery pack charging interface plug-in.

[0013] The above technical solution of the present application has the following beneficial effects: Compared with the traditional copper charging cable assembly, since the density of the aluminum alloy is only one-third of that of copper, under the premise of ensuring the same conductivity (i.e., using a 120 mm² aluminum cable assembly to replace a 95 mm² copper cable assembly), the weight of the cable assembly can be reduced by more than 40%, effectively reducing the body load of the light commercial vehicle, and the lightweight of the cable assembly directly reduces the energy consumption of the vehicle during driving, effectively improving the vehicle's range. From the raw material end, the cost of aluminum alloy is lower than that of red copper, which can directly reduce the material cost of the cable assembly (the cost of the cable part can be reduced by more than 50%); from the whole life cycle, combined with the whole vehicle energy consumption reduction effect brought by the lightweight of the cable assembly, the vehicle production and subsequent operation costs are further reduced. BRIEF DESCRIPTION OF DRAWINGS

[0014] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the present application and, together with the description, serve to explain the principles of the present application.

[0015] Figure 1 is a schematic view of the light commercial vehicle aluminum alloy charging cable assembly of the present application.

[0016] Figure 2 is a sectional view of the light commercial vehicle aluminum alloy charging cable assembly of the present application.

[0017] Wherein: 1 - DC charging socket, 2 - ground terminal, 3 - battery pack charging interface plug-in, 4 - main power cable, 5 - ground cable. DETAILED DESCRIPTION

[0018] Various exemplary embodiments of the present application will now be described in detail with reference to the accompanying drawings. Note that the relative arrangement, numerical expressions, and numerical values of components and steps set forth in these embodiments do not limit the scope of the present application unless otherwise specifically stated.

[0019] For new energy light commercial vehicles with high-power charging, vehicle weight reduction, and cost reduction requirements, the present application provides an aluminum alloy charging cable assembly for light commercial vehicles.

[0020] As shown in Figure 1 The overall cable assembly component assembly includes: a DC charging socket 1, a ground terminal 2, a battery pack charging interface plug-in 3, two main power cables 4 and one ground cable 5, and a communication signal cable integrated in the DC charging socket 1. Preferably, the DC charging socket is a DC01 DC charging socket (DC CHARGE SOCKET, NDQ-9Z(250A-1000V)-LG005 left cover), the ground terminal is a DC03 ground terminal (DC CHARGE PROTECT GROND model GRNT25-8), and the battery pack charging interface plug-in is a DC04 battery pack charging interface plug-in (model EVH6A-M2TJ-A).

[0021] The main power cable 4 is a 120mm² German standard (compliant with LV216 standard) shielded silicone cable, with an orange protective net added to the outside of the cable for protection. The cable conductor is an aluminum alloy conductor with a 6101 designation (with the same conductivity as a 95mm² copper charging cable). The conductor at one end of the main power cable 4 is connected to the copper terminal inside the DC charging socket 1 through ultrasonic welding technology (as shown in Figure 2 ), effectively solving the problems of increased contact resistance and increased heating caused by oxidation at the copper-aluminum connection. The conductor at the other end is also connected to the copper terminal inside the DC04 battery pack charging interface plug-in 3 through ultrasonic welding technology. In addition, to prevent electrochemical corrosion at the copper-aluminum connection under medium conditions (water, salt spray environment, grease, etc.), which can cause an increase in contact resistance and heating at the connection, the present solution takes additional heat shrink and glue protection measures after ultrasonic welding at the copper-aluminum connection, effectively isolating the medium.

[0022] The ground cable 5 is a 25mm² yellow-green copper cable, with a black corrugated tube added to the outside of the cable for protection. The cable conductor is a red copper conductor. The conductor at one end of the ground cable is connected to the copper terminal inside the DC01 DC charging socket 1 through traditional crimping, and the conductor at the other end is also connected to the DC03 ground terminal 2 through traditional crimping.

[0023] Although the present application has been disclosed in the above embodiments, it is not intended to limit the present application, and any person skilled in the art can make various modifications and changes without departing from the spirit and scope of the present application, and the scope of protection of the present application is defined by the claims and their equivalents.

Claims

1. An aluminum alloy charging cable assembly for light commercial vehicles, characterized by, It comprises a direct current charging socket (1), a grounding terminal (2), a battery pack charging interface plug-in (3), two main power cables (4) and a grounding cable (5); the conductors of the main power cables (4) are made of aluminum alloy material, and the two ends thereof are respectively connected with copper terminals in the direct current charging socket (1) and the battery pack charging interface plug-in (3) through ultrasonic welding; the conductor of the grounding cable (5) is made of copper material, and the two ends thereof are respectively connected with the direct current charging socket (1) and the grounding terminal (2).

2. The aluminum alloy charging cable assembly for light commercial vehicles as claimed in claim 1, characterized in that, The welding position of the aluminum alloy conductor of the main power cable (4) and the copper terminal is externally packaged with a corrosion-resistant sealing structure to isolate the medium.

3. The aluminum alloy charging cable assembly for light commercial vehicles according to claim 2, characterized in that, The corrosion-resistant sealing structure comprises a heat shrink tube and sealing glue filled between the heat shrink tube and the welding position.

4. The aluminum alloy charging cable assembly for light commercial vehicles according to claim 1, characterized in that, The conductor of the main power cable (4) is a shielding silica gel cable with a cross-sectional area of 120 mm².

5. The aluminum alloy charging cable assembly for light commercial vehicles as claimed in claim 4, characterized in that, The aluminum alloy material is aluminum alloy with a brand of 6101.

6. The aluminum alloy charging cable assembly for light commercial vehicles as claimed in claim 1, wherein, The grounding cable (5) is a yellow-green copper cable with a cross-sectional area of 25 mm², and the two ends thereof are respectively connected with the direct current charging socket (1) and the grounding terminal (2) through crimping.

7. The aluminum alloy charging cable assembly for light commercial vehicles as claimed in claim 1, wherein, The main power cable (4) is externally sleeved with a protective net, and the grounding cable (5) is externally sleeved with a black corrugated pipe.

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