New energy heavy truck high current charging gun

Abstract

The present application belongs to the technical field of new energy charging gun, especially relates to a new energy heavy truck large current charging gun, which comprises a shell, an electricity connection end, an elastic sealing assembly, a bending guide assembly and a tightening assembly. The shell adopts a half-split structure and is fixed by bolts, and the electricity connection end is detachably arranged at the head end of the shell. The elastic sealing assembly is arranged at the tail end of the shell and is used for sealing the connection between the tail end of the shell and the cable. The bending guide assembly is arranged in the shell. The present application adopts the elastic sealing assembly, the bending guide assembly and the tightening assembly to form a triple fixing system. Different from the traditional overall compression mode of fasteners, the triple fixing does not need to exert a large overall pressure on the cable, can greatly reduce the deformation degree of the cable during fixing, and further avoids the deformation of the liquid cooling pipe inside the cable due to external pressure, guarantees the normal heat dissipation function of the liquid cooling pipe, and ensures that the heat of the gun head terminal is promptly discharged.

Description

Technical Field

[0001] This invention belongs to the field of new energy charging gun technology, and in particular relates to a high-current charging gun for new energy heavy-duty trucks. Background Technology

[0002] The development of the new energy heavy truck industry has driven the widespread application of high-current charging guns, which need to withstand greater charging currents. Therefore, they are equipped with internal liquid cooling pipes for heat dissipation, and the structural design must take into account conductivity, heat dissipation, and mechanical protection performance.

[0003] Traditional high-current charging guns use fasteners to press the cable together to ensure tensile strength and sealing performance. However, because the cable is thin and the liquid cooling pipe is closely arranged with the cable, it is easy to compress the liquid cooling pipe and cause it to deform, thereby reducing the cooling efficiency and failing to dissipate the heat from the gun head terminals in time.

[0004] Deformation of the liquid cooling pipe can cause overheating of the charging gun terminals, which not only triggers overheat protection to interrupt charging, but also poses safety hazards such as terminal melting in severe cases. This cannot meet the needs of new energy heavy-duty trucks. Therefore, there is an urgent need for a high-current charging gun for new energy heavy-duty trucks to solve this defect. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a high-current charging gun for new energy heavy-duty trucks, which solves the problems mentioned in the background section.

[0006] To achieve the above objectives, this application provides the following technical solution: This invention provides a high-current charging gun for new energy heavy-duty trucks, including a housing, a power connector, an elastic sealing assembly, a bending guide assembly, and a tightening assembly. The housing adopts a split-type structure and is fixed with bolts. The power connector is detachably located at the front end of the housing. The elastic sealing assembly is located at the rear end of the housing and is used to seal the connection between the rear end of the housing and the cable. The bending guide assembly is located inside the housing and includes a first arc-shaped protrusion and a second arc-shaped protrusion fixedly disposed on the inner wall of the housing cavity. While the cable is tightened, the first arc-shaped protrusion, the second arc-shaped protrusion, and the inner wall of the housing work together to compress and bend the cable. The tightening assembly includes a cable bundler and a cable winder located inside the housing near the power connector. The cable bundler limits the cable end, and the exposed thick wire core from the cable end is wound around the corresponding cable winder, keeping the exposed wire core taut with the cable body. The elastic sealing component seals the connection between the outer casing and the cable while simultaneously applying pressure to the cable, achieving a first layer of elastic compression and fixation. The bending guide component then compresses and bends the cable, achieving a second layer of compression and fixation. Finally, the tightening component wraps the exposed thick wire core around the cable with a winding device, keeping the thick wire core and the cable taut and generating mutual tension, thus achieving a third layer of tension and fixation for the cable.

[0007] According to an advantageous embodiment, the resilient sealing assembly includes a rubber sealing sleeve and a locking sleeve, the rubber sealing sleeve being fitted onto the surface of the cable, and the locking sleeve being threadedly connected to the tail end of the housing and pressing against a portion of the surface of the rubber sealing sleeve.

[0008] According to an advantageous embodiment, the rubber sealing sleeve includes a cylindrical section, a conical section, and an extended ring, the extended ring being disposed at the junction of the cylindrical section and the conical section, and the extended ring being fitted onto the end face of the tail end of the outer shell.

[0009] According to an advantageous embodiment, the locking sleeve includes a threaded section and a compression section. The threaded section is threadedly connected to the outer wall of the tail end of the housing, and the inner cavity of the compression section is configured as a conical structure. The rotation of the threaded section causes the compression section to simultaneously abut against the outer ring and the conical section.

[0010] According to an advantageous embodiment, a concave arc surface is provided on the inner wall of the outer casing at the position opposite to the first arc-shaped protrusion.

[0011] According to an advantageous embodiment, the cable bundler includes a fixed base that is fixedly connected to the inner wall of the housing via a bracket. A slot is provided on the side of the fixed base away from the power terminal, into which the cable end is inserted. A plurality of through holes communicating with the slot are provided on the side of the fixed base near the power terminal, through which the exposed wire core of the cable end passes and connects to the cable bundler.

[0012] According to an advantageous embodiment, the winding device includes a winding post fixedly disposed within a housing, a wire core wound on the winding post, and a pressure plate threaded onto the winding post.

[0013] According to an advantageous embodiment, a positioning support post is slidably inserted into the end of the winding post, and the positioning support post is fixedly connected to the outer casing.

[0014] Compared with existing technologies, the high-current charging gun for new energy heavy-duty trucks provided in this invention has the following beneficial effects: In this invention, a triple-fixing system is formed by an elastic sealing component, a bending guide component, and a tightening component. The elastic sealing component provides a first-level elastic compression fixation of the cable; the bending guide component provides a second-level compression fixation through bending; and the tightening component provides a third-level tension fixation by wrapping and tightening the cable core. Unlike traditional overall clamping methods, this triple-fixing system does not require applying enormous overall pressure to the cable, significantly reducing the degree of deformation during cable fixing. This prevents deformation of the internal liquid cooling pipe due to external pressure, ensuring normal heat dissipation of the liquid cooling pipe and timely heat dissipation from the gun head terminals. While ensuring that the cable's sealing, tensile strength, and torsional strength meet standards, this invention effectively solves the core problems of traditional charging guns, such as liquid cooling pipe deformation, reduced cooling efficiency, and overheating of the gun head terminals caused by overall clamping of the cable with fasteners. It meets the high-current charging requirements of new energy heavy-duty trucks while improving charging safety and equipment stability. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the external three-dimensional structure of the present invention.

[0016] Figure 2 This is a side view sectional planar structural diagram of the present invention.

[0017] Figure 3 This is a partial cross-sectional three-dimensional structural diagram of the outer shell in this invention.

[0018] Figure 4 This is a schematic diagram of the front cross-sectional planar structure of the outer shell in this invention.

[0019] The reference numerals in the figure are as follows: 1. Outer shell; 11. Concave arc surface; 2. Electrical terminal; 3. Elastic sealing assembly; 31. Rubber sealing sleeve; 311. Cylindrical section; 312. Conical section; 313. Outer ring; 32. Locking sleeve; 321. Threaded section; 322. Extrusion section; 4. Bending guide assembly; 41. First arc-shaped protrusion; 42. Second arc-shaped protrusion; 5. Tightening assembly; 51. Cable bundler; 52. Cable winder; 521. Winding post; 522. Pressure plate; 523. Positioning support post; 100. Cable; 200. Wire core. Detailed Implementation

[0020] The following is in conjunction with the appendix Figure 1 -Appendix Figure 4 This application will now be described in further detail.

[0021] Please refer to the following: Figure 1 and Figure 2 A high-current charging gun for new energy heavy-duty trucks includes a housing 1, a power connector 2, an elastic sealing assembly 3, a bending guide assembly 4, and a tightening assembly 5. The housing 1 adopts a split structure and is fixed with bolts. The power connector 2 is detachably located at the front end of the housing 1. The bending guide assembly 4 and the tightening assembly 5 are both located inside the housing 1.

[0022] In practice, the elastic sealing component 3 seals the connection between the tail of the outer shell 1 and the outside of the cable 100, and applies pressure to the cable 100, achieving a first layer of elastic compression fixation. Then, the portion of the cable 100 inside the outer shell 1 and near its tail is compressed and bent by the bending guide component 4, limiting the cable 100's twisting while further improving its anti-pull performance, achieving a second layer of compression fixation. Finally, the tightening component 5 wraps and fixes the exposed thick core 200, keeping the thick core 200 and the cable 100 taut, thus generating mutual tension and achieving a third layer of tension fixation for the cable 100. While ensuring that the cable 100's sealing, pull resistance, and torsion resistance all meet standards, this significantly reduces the degree of deformation when the cable 100 is fixed to the outer shell 1, thereby preventing the internal liquid cooling tube of the cable 100 from deforming under immense external fixing pressure. This reduces the risk of overheating of the gun head terminals due to liquid cooling tube deformation, triggering overheat protection to interrupt charging, and in severe cases, causing terminal melting.

[0023] The outer shell 1 is made of PC / ABS alloy, which has good impact resistance, mechanical strength, and flame retardant properties, meeting the structural strength and safety protection requirements of the charging gun outer shell 1 during use. The power connector 2 is made of silver-plated copper alloy.

[0024] See Figure 2 To ensure a tight seal and pressure resistance at the connection point between the tail end of the outer casing 1 and the cable 100, the elastic sealing assembly 3 includes a rubber sealing sleeve 31 and a locking sleeve 32. The rubber sealing sleeve 31 is fitted onto the surface of the cable 100, and the locking sleeve 32 is threadedly connected to the tail end of the outer casing 1 and presses against a portion of the surface of the rubber sealing sleeve 31. The rubber sealing sleeve 31 includes a cylindrical section 311, a conical section 312, and an extended ring 313. The extended ring 313 is located at the junction of the cylindrical section 311 and the conical section 312 and fits against the end face of the tail end of the outer casing 1. The locking sleeve 32 includes a threaded section 321 and a compression section 322. The threaded section 321 is threadedly connected to the outer wall of the tail end of the outer casing 1, and the inner cavity of the compression section 322 is a conical structure.

[0025] In practice, the rubber sealing sleeve 31 is filled at the connection between the tail end of the outer shell 1 and the cable 100. Then, the installer controls the threaded section 321 of the locking sleeve 32 to rotate, causing the extrusion section 322 to simultaneously abut against the outer ring 313 and the conical section 312. This makes the conical section of the rubber sealing sleeve 31 fit more tightly onto the surface of the cable 100, while the outer ring 313 of the rubber sealing sleeve 31 fits tightly against the end face of the tail end of the outer shell 1, ensuring the sealing performance between the rubber sealing sleeve 31 and the connection between the tail end of the outer shell 1 and the cable 100. In addition, the locking sleeve 32 also indirectly and elastically fixes the corresponding position of the tail end of the outer shell 1 and the cable 100, improving the stability of the cable 100 installed on the outer shell 1.

[0026] See Figure 2 To further improve the stability of the cable 100 mounted on the housing 1, the bending guide assembly 4 includes a first arc-shaped protrusion 41 and a second arc-shaped protrusion 42 fixedly disposed on the inner wall of the housing 1 cavity. As the cable 100 is tightened, the first arc-shaped protrusion 41, the second arc-shaped protrusion 42, and the inner wall of the housing 1 work together to compress and bend the cable 100. A concave arc surface 11 is provided on the inner wall of the housing 1, directly opposite the first arc-shaped protrusion 41.

[0027] In operation, the first arc-shaped protrusion 41 and the concave arc surface 11 on the inner wall of the outer casing 1 form a bending guide channel. The cross-sectional diameter of this bending guide channel is 0.5-1 cm smaller than the diameter of the cable 100. This causes the cable 100 to bend within the channel while taut and be subjected to the compressive force of the bending guide channel. The cable 100 undergoes slight deformation while being compressed within the bending guide channel. Then, the other end of the cable 100 is bent again through the second arc-shaped protrusion 42. By bending the cable 100 twice, the anti-torsion ability of the cable 100 is improved, and the fixing effect of the cable 100 within the outer casing 1 is further enhanced, thereby increasing the tensile strength of the cable 100.

[0028] It should be noted that the bending angle radius of the cable 100 through the first arc-shaped protrusion 41 and the second arc-shaped protrusion 42 has been repeatedly calculated by those skilled in the art to avoid excessive bending of the cable 100 and resulting bending deformation.

[0029] See Figures 2-4 To further improve the stability of the cable 100 within the housing 1 and prevent excessive compression and deformation, the tightening component 5 in this solution includes a cable tie 51 and a cable winder 52 located inside the housing 1 near the power connector 2. The cable tie 51 includes a fixing base fixedly connected to the inner wall of the housing 1 via a bracket. A slot is provided on the side of the fixing base away from the power connector 2, and multiple through holes communicating with the slot are provided on the side of the fixing base near the power connector 2. The exposed wire core 200 of the cable 100 passes through the through holes and connects to the cable winder 52. The cable winder 52 includes a winding post 521 fixedly installed inside the housing 1, and a pressure plate 522 is threaded onto the winding post 521. Both the slot and the through holes are lined with buffer pads to cushion and protect the wire core 200 when subjected to tension.

[0030] In practice, the end of cable 100 is inserted into the slot to limit its position. Then, the exposed thick wire core 200 at the end of cable 100 is wound around the winding post 521. While ensuring that the wire core 200 and the end of cable 100 are taut, the wire core 200 is wound around the winding post 521. The other end of the thick wire core 200 is connected to the power terminal. Finally, the pressure plate 522 is screwed onto the winding post 521 and the wound wire core 200 is pressed tightly to reduce the risk of the wire core 200 loosening under tension. This allows the thick wire core 200 to provide a certain amount of anti-pull force for the end of cable 100, further improving the stability of cable 100 within the outer casing 1.

[0031] It should be noted that the thick wire core 200 wound on the winding post 521 is normally kept taut with the end of the cable 100, and the tension between the two is minimal and will not affect the conductivity of the wire core 200. Only when subjected to a huge pulling force between the charging gun and the external cable 100 will the thick wire core 200 provide anti-pulling force in emergency situations.

[0032] To improve the strength of the winding post 521, a positioning support post 523 is slidably inserted into the end of the winding post 521, and the positioning support post 523 is fixedly connected to the outer casing 1. During the assembly of the outer casing 1, the positioning support post 523 is inserted into the winding post 521 to improve the tensile strength of the winding post 521.

[0033] In summary, this solution achieves a first layer of elastic compression and fixation for the cable 100 through the elastic sealing component 3, a second layer of compression and fixation through the bending guide component 4, and a third layer of tension and fixation through the winding and tightening component 5. Unlike traditional fasteners that use overall compression, this triple fixation does not require applying significant overall pressure to the cable 100, which can greatly reduce the degree of deformation of the cable 100 during fixation. This prevents the internal liquid cooling pipe of the cable 100 from deforming due to external pressure, ensuring the normal heat dissipation function of the liquid cooling pipe and ensuring timely heat dissipation from the gun head terminals.

[0034] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0035] Furthermore, the terms "first," "second," "number one," and "number two" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first," "second," "number one," or "number two" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0036] In this invention, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," "link," and "fix" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0037] The embodiments described herein are preferred embodiments of the present invention and are not intended to limit the scope of protection of the present invention. Therefore, all equivalent changes made in accordance with the structure, shape, and principle of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A high-current charging gun for new energy heavy-duty trucks, characterized in that: Includes housing, electrical terminals, resilient sealing assembly, bending guide assembly, and tightening assembly; The outer casing adopts a split structure and is fixed with bolts, and the power connection terminal is detachably set at the first end of the outer casing; The elastic sealing component is located at the tail end of the housing and is used to seal the connection between the tail end of the housing and the cable. The bending guide assembly is located inside the housing. The bending guide assembly includes a first arc-shaped protrusion and a second arc-shaped protrusion fixedly disposed on the inner wall of the housing cavity. When the cable is tightened, the first arc-shaped protrusion, the second arc-shaped protrusion and the inner wall of the housing cooperate to squeeze and bend the cable together. The tightening assembly includes a cable tie and a cable winder disposed inside the housing and near the power connection end. The cable tie limits the cable end, and the thick core exposed from the cable end is wound around the corresponding cable winder, so that the exposed core of the cable end is kept taut with the cable body. The cable bundler includes a fixed base that is fixedly connected to the inner wall of the housing via a bracket. A slot is provided on the side of the fixed base away from the power terminal, and the cable end is inserted into the slot. Multiple wire holes connected to the slot are provided on the side of the fixed base near the power terminal, and the exposed wire core of the cable end passes through the wire holes and connects to the cable bundler. The elastic sealing component seals the connection between the outer casing and the cable while simultaneously applying pressure to the cable, achieving a first layer of elastic compression and fixation. The bending guide component then compresses and bends the cable, achieving a second layer of compression and fixation. Finally, the tightening component wraps the exposed thick wire core around the cable with a winding device, keeping the thick wire core and the cable taut and generating mutual tension, thus achieving a third layer of tension and fixation for the cable.

2. The high-current charging gun for new energy heavy-duty trucks according to claim 1, characterized in that, The elastic sealing assembly includes a rubber sealing sleeve and a locking sleeve. The rubber sealing sleeve is fitted onto the surface of the cable, and the locking sleeve is threaded to the tail end of the housing and squeezes a portion of the surface of the rubber sealing sleeve.

3. The high-current charging gun for new energy heavy-duty trucks according to claim 2, characterized in that, The rubber sealing sleeve includes a cylindrical section, a conical section, and an extended ring. The extended ring is located at the junction of the cylindrical section and the conical section and is attached to the end face of the tail end of the outer shell.

4. A high-current charging gun for new energy heavy-duty trucks according to claim 3, characterized in that, The locking sleeve includes a threaded section and a pressing section. The threaded section is threadedly connected to the outer wall of the tail end of the housing. The inner cavity of the pressing section is set as a conical structure. The rotation of the threaded section causes the pressing section to simultaneously abut against the outer ring and the conical section.

5. A high-current charging gun for new energy heavy-duty trucks according to claim 1, characterized in that, The inner wall of the outer shell has a concave arc surface located opposite the first arc-shaped protrusion.

6. A high-current charging gun for new energy heavy-duty trucks according to claim 1, characterized in that, The winding device includes a winding post fixedly disposed inside the housing, the wire core is wound on the winding post, and a pressure plate is threaded on the winding post.

7. A high-current charging gun for new energy heavy-duty trucks according to claim 6, characterized in that, The end of the winding post is slidably inserted with a positioning support post, which is fixedly connected to the outer shell.

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