A high-pressure-resistant and cyclic-bending-resistant high-power electric cable for new energy vehicles

Abstract

The application provides a new energy vehicle high-power electric cable with high-pressure cycle bending resistance, and relates to the technical field of cables.The new energy vehicle high-power electric cable with high-pressure cycle bending resistance comprises a cable body connected with a charging gun, a protection assembly and a thermal cycle assembly.The cable body comprises an outer sheath and a conductor.The conductor is arranged inside the outer sheath.The inner cavity of the outer sheath is filled with a filler for maintaining the cylindrical shape of the cable body.The protection assembly comprises multiple protection sleeves arranged on the cable body.The multiple protection sleeves are movably connected through a connecting assembly.The protection assembly is used for limiting the bending position of the cable body.The multiple movably connected protection sleeves can limit the bending position of the cable body through the protection assembly, so that the cable body is prevented from being excessively bent at one position, the damage of the conductor and the outer sheath caused by frequent bending is reduced, and the service life is prolonged.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a high-power power cable for new energy vehicles that is resistant to high-voltage cyclic bending. Background Technology

[0002] The rapid development of the new energy vehicle industry and the widespread use of high-voltage fast charging technology have placed higher demands on the performance of charging power cables. Charging cables are mainly responsible for transmitting high-power electrical energy between the vehicle and the charging pile, and their performance is directly related to the safety and stability of vehicle charging. These cables are generally composed of conductors, insulation layers, shielding layers and outer sheaths, and need to adapt to complex operating environments and have characteristics such as high temperature resistance and bending resistance.

[0003] Currently, high-power charging cables for new energy vehicles have the following shortcomings in practical use: In terms of bending resistance, frequent bending over a long period of time can easily lead to conductor breakage and insulation layer cracking, which not only poses safety hazards but also shortens the service life; In terms of temperature adaptability, at low temperatures, the flexibility of the cable insulation material decreases, making it more prone to cracking when bent; At high temperatures, the heat generated by the conductor during high-current charging will further increase the overall temperature of the cable. If the heat cannot be dissipated in time, it will accelerate the aging of the insulation layer, which can easily lead to a reduction in the safety performance of the power cable. Summary of the Invention

[0004] In view of the shortcomings of the prior art, the purpose of this invention is to provide a high-power power cable for new energy vehicles that can withstand high-voltage cyclic bending, which can solve the problems existing in the prior art: in terms of bending resistance, long-term frequent bending can easily lead to conductor wire breakage and insulation layer cracking, which not only brings safety hazards but also shortens the service life; in terms of temperature adaptability, at low temperatures, the flexibility of the cable insulation material decreases, and it is more prone to cracking when bending; while at high temperatures, the conductor heats up during high-current charging, which further increases the overall temperature of the cable. If the heat cannot be dissipated in time, it will accelerate the aging of the insulation layer, leading to a further reduction in safety performance.

[0005] This invention proposes a high-power power cable for new energy vehicles that is resistant to high-voltage cyclic bending, comprising: a cable body connected to a charging gun, a protective component, and a thermal cycling component; The cable body includes an outer sheath and a conductor. The conductor is disposed inside the outer sheath, and the inner cavity of the outer sheath is filled with a filler to maintain the cable body in a cylindrical shape. The protective assembly includes multiple protective sleeves fitted onto the cable body, and the multiple protective sleeves are movably connected to each other by a connecting assembly. The protective assembly is used to limit the bending position of the cable body. The thermal circulation assembly includes an air delivery channel formed inside the filling material, and a heating ring is provided inside the air delivery channel; the thermal circulation assembly also includes an external circulation pipe group and an internal circulation pipe group, and the air delivery channel can be selectively connected to one of the external circulation pipe group and the internal circulation pipe group.

[0006] Furthermore, the protective sleeve is formed by splicing multiple collar units, each collar unit including a central ring, with multiple protrusions evenly distributed on both side walls of the central ring; adjacent collar units are staggered so that the protrusion of one unit can be movably inserted into the gap between adjacent protrusions of the other unit; a movable groove is provided on the protrusion on one side of the collar unit, and a fixing rod is fixedly provided between adjacent protrusions on the other side; adjacent collar units are interconnected through the insertion and cooperation of the fixing rod and the movable groove.

[0007] Furthermore, the connecting components are arranged in multiple sets and symmetrically between two adjacent protective sleeves; the connecting components include two mounting seats, which are rotatably mounted on the middle annular sidewall of the corresponding collar unit in two adjacent protective sleeves. The mounting seats have a U-shaped structure, and mounting grooves are provided on the inner walls of both sides of the mounting seats. A ball joint is movably mounted in the middle of the mounting groove. The ends of the two corresponding ball joints on two adjacent protective sleeves are movably connected through a universal joint.

[0008] Furthermore, a fixing tube is fixed to one end of the cable body near the charging gun, a circular fixing plate is fixed to the outer wall of the fixing tube, a rotating housing is rotatably mounted on the side of the fixing plate, and the outer circulation pipe assembly and the inner circulation pipe assembly are disposed on the inner wall of the rotating housing. The external circulation pipe assembly includes multiple mounting pipes evenly distributed on the rotating housing. One end of the mounting pipe facing the center of the rotating housing is sealed and slidably fitted with a movable sleeve. A magnetic block is fixed at the end of the movable sleeve. The other end of the mounting pipe extends through to the outside of the rotating housing. A filter membrane is provided on the end of the mounting pipe. The internal circulation pipe assembly includes multiple mounting pipes II, which are respectively arranged in the middle of two adjacent mounting pipes I. The end of the mounting pipe II facing the center of the rotating housing is sealed and slidably fitted with a movable sleeve II. A hollow ring is fixed on the inner wall of the rotating housing, and each mounting pipe II is connected to the inner cavity of the hollow ring through a connecting pipe. Multiple L-shaped connecting pipes are fixed on the fixed pipe. One end of the connecting pipe is fixedly connected to the port of the gas transmission channel, and the other end of the connecting pipe faces the outer circulation pipe group and the inner circulation pipe group; a fan is installed inside one of the connecting pipes.

[0009] Furthermore, a motor is fixed to the side wall of the fixed plate, and a gear is fixed to the output end of the motor; a gear ring is provided on the rotating housing, and the gear ring meshes with the gear. Through the meshing of the gear and the gear ring, the rotating housing is driven to rotate around the outer periphery of the fixed plate.

[0010] Furthermore, the cable body is fixed with a fixed sleeve at the end away from the charging gun, the conductor inside the cable body passes through the fixed sleeve and is electrically connected to the power supply equipment, and a connecting cavity is provided inside the fixed sleeve to connect the ends of multiple gas delivery channels.

[0011] Furthermore, the protective sleeve is at least partially composed of a thermochromic material that changes color when the temperature exceeds a preset threshold to indicate abnormal temperature areas of the cable body.

[0012] Furthermore, a temperature sensor is detachably mounted on the fixed sleeve.

[0013] Furthermore, a spring is fitted on the outer side of the first movable sleeve, one end of the spring is fixedly connected to the end of the first movable sleeve, and the other end of the spring is fixedly connected to the inner wall of the rotating housing; a spring is fitted on the outer side of the second movable sleeve, one end of the spring is fixedly connected to the end of the second movable sleeve, and the other end of the spring is fixedly connected to the inner wall of the rotating housing.

[0014] Furthermore, a hollow end cap is detachably installed at the end of the mounting tube extending to the outside of the rotating housing, and the filter membrane is disposed inside the end cap.

[0015] The beneficial effects of the technical solutions provided by the embodiments of the present invention include at least the following: 1. By setting up protective components, multiple movable protective sleeves can limit the bending position of the cable body, prevent the cable body from being excessively bent in one place, reduce the damage to the conductor and outer sheath caused by frequent bending, help reduce the probability of conductor wire breakage and insulation layer cracking, thereby improving the bending resistance of the cable and extending its service life. 2. A thermal circulation component is installed. When in a low-temperature environment, the gas supply channel is connected to the inner circulation pipe group, and the heating ring heats the gas in the channel, keeping the cable at a suitable operating temperature, ensuring the flexibility of the cable insulation material, and preventing cracks caused by bending at low temperatures. When in a high-temperature environment and charging with high current, the gas supply channel switches to be connected to the outer circulation pipe group, and external gas continuously flows through the gas supply channel, carrying away the heat generated by the conductor, improving heat dissipation efficiency, preventing the overall cable temperature from becoming too high, delaying the aging of the insulation layer, and thus improving the safety performance of the cable. 3. The protective sleeve made of thermochromic material can change color when the local temperature of the cable exceeds a preset threshold, making it easy for users to intuitively discover abnormal temperature areas of the cable, facilitating timely investigation of safety hazards and improving the efficiency of fault diagnosis; the temperature sensor that can be detachably installed on the fixed sleeve can detect the internal gas temperature of the cable in real time, facilitating automatic control of the switching of the thermal circulation path and the working power of the heating and fan, which helps to improve the intelligence level of the cable. Attached Figure Description

[0016] The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Throughout the drawings, the same reference numerals denote the same parts. Obviously, the drawings described below are merely some embodiments of the present invention, and those skilled in the art can obtain other drawings based on these drawings without any creative effort.

[0017] Figure 1 This is a schematic diagram of the overall structure of the present invention.

[0018] Figure 2 This is a schematic diagram of the structure of the protective component and the connecting component in this invention.

[0019] Figure 3 This is a schematic diagram of the collar unit in this invention.

[0020] Figure 4 This is a schematic diagram of the protective sleeve undergoing bending deformation in this invention.

[0021] Figure 5 This is a schematic diagram of the connecting component in this invention.

[0022] Figure 6 This is a partial cross-sectional view of the thermal cycling component in this invention.

[0023] Figure 7 This is another partial cross-sectional view of the thermal cycling component in this invention.

[0024] Figure 8 yes Figure 7 Enlarged schematic diagram of the structure at point A in the middle.

[0025] Figure 9 This is a schematic diagram of the internal structure of the fixing sleeve in this invention.

[0026] Figure 10 This is a cross-sectional schematic diagram of the cable body in this invention.

[0027] Figure 11 This is a schematic diagram of the three-dimensional structure of the rotating shell and end cap separated in this invention.

[0028] Explanation of reference numerals in the attached drawings: 100, cable; 101, outer sheath; 102, filler; 103, conductor; 104, gas delivery channel; 105, fixing sleeve; 106, connecting cavity; 107, temperature sensor; 108, heating ring; 200, protective assembly; 201, protective sleeve; 202, collar unit; 203, protrusion; 204, movable groove; 205, fixing rod; 300, thermal circulation assembly; 301, fixing pipe; 302, fixing plate; 3 03. Rotating housing; 304. Mounting tube one; 305. Movable sleeve one; 306. Connecting pipe; 307. Mounting tube two; 308. Movable sleeve two; 309. Hollow ring; 310. Connecting pipe; 311. Magnetic block; 312. Fan; 313. Filter membrane; 314. Gear ring; 315. Gear; 316. Motor; 400. Connecting assembly; 401. Mounting base; 402. Mounting groove; 403. Ball joint connecting rod; 404. Universal joint. Detailed Implementation

[0029] To enable those skilled in the art to better understand the technical solutions in the embodiments of the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0030] Furthermore, descriptions of well-known structures and techniques are omitted in the following description to avoid unnecessarily obscuring the concepts disclosed in this invention.

[0031] Exemplary embodiments will now be described in detail, examples of which are illustrated in the accompanying drawings. When the following description relates to the drawings, unless otherwise indicated, the same numbers in different drawings denote the same or similar elements. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present invention.

[0032] Reference manual attached Figures 1 to 11 The present invention provides a structure for a high-power power cable for new energy vehicles that is resistant to high-voltage cyclic bending, comprising: a cable body 100 connected to a charging gun, a protective component 200, and a thermal circulation component 300; The cable 100 body includes an outer sheath 101 and a conductor 103. The conductor 103 is disposed inside the outer sheath 101. The inner cavity of the outer sheath 101 is filled with filler 102 to maintain the cable 100 body in a cylindrical shape, and the filler 102 wraps around the outside of the conductor 103. The protective assembly 200 includes a plurality of protective sleeves 201 sleeved on the cable 100 body, and the plurality of protective sleeves 201 are movably connected to each other by a connecting assembly 400. The protective assembly 200 is used to limit the bending position of the cable 100 body. The heat circulation assembly 300 includes an air supply channel 104 formed inside the filler 102, and a heating ring 108 is provided inside the air supply channel 104; the heat circulation assembly 300 also includes an external circulation pipe group and an internal circulation pipe group, and the air supply channel 104 can be selectively connected to one of the external circulation pipe group and the internal circulation pipe group.

[0033] In this embodiment of the invention, the number of protective sleeves 201 can be selected according to the actual length of the cable 100. The appropriate number of protective sleeves 201 are fitted onto the outside of the cable 100 body, which can limit the bending position of the cable 100 body, making it less likely to bend significantly in the area covered by the protective sleeves 201, and bending only occurs at the connecting component 400. During use, the position of the protective sleeves 201 can also be adjusted by manually pushing them, thereby changing the bending point and avoiding fatigue damage to the cable 100 body due to long-term bending in the same position. This effectively increases the bending cycle resistance of the cable 100 and extends its service life.

[0034] Meanwhile, the heat circulation component 300 can selectively switch between external circulation and internal circulation modes: when the ambient temperature is low, the heating ring 108 is activated to heat the air in the internal circulation air path, and the circulating airflow evenly transfers heat to the entire cable 100, ensuring that the cable 100 can maintain good flexibility in low-temperature environments and avoid low-temperature brittleness; when the cable 100 transmits high power and the temperature rises, it switches to external circulation mode, and the external airflow enters the air delivery channel 104 through the external circulation pipe group, carrying away the heat inside the cable 100, realizing active heat dissipation, avoiding the cable 100 from aging due to long-term high-temperature operation, and effectively improving the service life of the cable 100.

[0035] Furthermore, by moving the protective sleeve 201 outside the cable 100 body, when a break is found in a certain part of the cable 100 body, the connecting component 400 can be tied and fixed to the outside of the cable body using existing cable ties. This fixes the protective sleeve 201 at the break location, providing temporary protection to the break point, preventing further external friction and damage, improving safety during use, extending the service life of the cable 100, and avoiding safety accidents caused by failure to replace it in time.

[0036] Furthermore, the filler 102 can be made of silicone rubber-based composite filler with excellent thermal conductivity. Silicone rubber itself has good insulation and flexibility. Combined with the added high thermal conductivity ceramic filler, it can maintain the cylindrical shape of the cable body, buffer the stress brought by bending to the conductor 103 and insulation layer, and quickly conduct the heat generated by the conductor 103 to the air supply channel 104. Combined with the heat circulation component 300, it can improve the overall heat dissipation efficiency without hindering the heat transfer. At the same time, it has good aging resistance and can adapt to the working environment of long-term cyclic bending of the cable 100.

[0037] In one possible implementation, the protective sleeve 201 is formed by splicing together multiple collar units 202. Each collar unit 202 includes a central ring, and multiple protrusions 203 are evenly distributed on the two side walls of the central ring. Two adjacent collar units 202 are staggered so that the protrusions 203 of one unit can be movably inserted into the gap between the adjacent protrusions 203 of the other unit. A movable groove 204 is provided on the protrusions 203 on one side of the collar unit 202, and a fixing rod 205 is fixedly provided between the adjacent protrusions 203 on the other side. Two adjacent collar units 202 are connected to each other by the insertion and cooperation of the fixing rod 205 and the movable groove 204.

[0038] In this embodiment of the invention, adjacent collar units 202 can slide and deflect relative to each other through the cooperation of the fixed rod 205 and the movable groove 204. Multiple collar units 202 can be spliced ​​together to form a self-adaptive protective sleeve 201. When the cable 100 bends, the protective sleeve 201 can expand and contract synchronously with the cable 100 without affecting the normal bending and use of the cable 100. For details, please refer to the instruction manual. Figure 4 At this time, the protective sleeve 201 is in a slightly bent state to accommodate the bending of the cable body.

[0039] In one possible implementation, the connecting components 400 are arranged in multiple sets and symmetrically between two adjacent protective sleeves 201. The connecting components 400 include two mounting seats 401, which are rotatably mounted on the middle annular sidewall of the corresponding collar unit 202 in the two adjacent protective sleeves 201. The mounting seats 401 have a U-shaped structure, and mounting grooves 402 are provided on the inner walls of both sides of the mounting seats 401. A ball joint connecting rod 403 is movably mounted in the middle of the mounting groove 402. The ends of the two corresponding ball joint connecting rods 403 on the two adjacent protective sleeves 201 are movably connected through a universal joint 404.

[0040] In this embodiment of the invention, adjacent protective sleeves 201 are connected by a universal joint 404 and a ball joint 403, which can achieve free rotation in multiple directions. While ensuring bending flexibility, the bending force can be limited to the connection position between adjacent protective sleeves 201, avoiding excessive bending of the cable 100 body in some areas, and further reducing the probability of fatigue damage caused by long-term bending of the cable 100.

[0041] In this embodiment of the invention, three or more protective sleeves 201 can be movably connected by a connecting component 400, and then multiple protective sleeves 201 can be installed on the cable body at positions that are frequently in contact with the ground or are dragged and bent. The protective sleeves 201 can limit the large bending of the cable body of different lengths in different areas. Specifically, the more protective sleeves 201 there are, the greater the degree of restriction on the bending of the cable body in that area. In addition, the protective sleeves 201 can also reduce the friction between the cable body and the ground, further preventing the cable 100 from wearing out.

[0042] In one possible implementation, a fixing tube 301 is fixed to one end of the cable 100 body near the charging gun. The fixing tube 301 is fixedly connected to the charging gun. A circular fixing plate 302 is fixed on the outer wall of the fixing tube 301. A rotating housing 303 is rotatably mounted on the side of the fixing plate 302. An external circulation pipe group and an internal circulation pipe group are arranged on the inner wall of the rotating housing 303. The number of external circulation pipe groups and internal circulation pipe groups corresponds to the number of gas delivery channels 104. The external circulation pipe assembly includes multiple mounting pipes 304 evenly distributed on the rotating housing 303. One end of the mounting pipe 304 facing the center of the rotating housing 303 is sealed and slidably fitted with a movable sleeve 305. A magnetic block 311 is fixed to the end of the movable sleeve 305. The magnetic block 311 can attract and fix the ends of the movable sleeve 305 and the movable sleeve 308, so that the pipes are connected and connected. The magnetic block 311 can also be a ring electromagnet of the prior art. After the movable sleeve 305 or the movable sleeve 308 rotates to the outside of the port of the connecting pipe 306, the electromagnet can be energized to attract and fix the movable sleeve 305 or the movable sleeve 308. Specifically, the ends of the movable sleeve 305 and the movable sleeve 308 can be made of magnetic material to facilitate the electromagnet to attract and fix them. The other end of the mounting pipe 304 extends through to the outside of the rotating housing 303. A filter membrane 313 is provided on the end of the mounting pipe 304. The internal circulation pipe assembly includes multiple mounting pipes 307, which are respectively arranged between two adjacent mounting pipes 304. The end of the mounting pipe 307 facing the center of the rotating housing 303 is sealed and slidably fitted with a movable sleeve 308. A hollow ring 309 is fixed on the inner wall of the rotating housing 303, and each mounting pipe 307 is connected to the inner cavity of the hollow ring 309 through a connecting pipe 310. Multiple L-shaped connecting pipes 306 are fixed on the fixed pipe 301. One end of the connecting pipe 306 is fixedly connected to the port of the air supply channel 104, and the other end of the connecting pipe 306 faces the external circulation pipe group and the internal circulation pipe group. A fan 312 is installed inside one of the connecting pipes 306. The fan 312 can be equipped with fan blades at the output end of the existing motor. The fan blades are driven by the motor to achieve the ventilation effect.

[0043] In one possible implementation, a motor 316 is fixed to the side wall of the fixed plate 302, and a gear 315 is fixed to the output end of the motor 316. A gear ring 314 is provided on the rotating housing 303, and the gear ring 314 meshes with the gear 315. Through the meshing and engagement of the gear 315 and the gear ring 314, the rotating housing 303 is driven to rotate around the outer periphery of the fixed plate 302. Furthermore, an end cap is detachably installed on the outer end of the rotating housing to cover the rotating structures such as the gear 315 and the gear ring 314, providing protection.

[0044] In one possible implementation, a fixing sleeve 105 is fixed to one end of the cable 100 body away from the charging gun. The conductor 103 inside the cable 100 body passes through the fixing sleeve 105 and is electrically connected to the power supply equipment. A connecting cavity 106 is provided inside the fixing sleeve 105 for connecting the ends of multiple gas supply channels 104.

[0045] In this embodiment of the invention, when it is necessary to switch the circulation mode, the motor 316 drives the rotating housing 303 to rotate through the meshing of the gear 315 and the gear ring 314, so that the movable sleeve 305 is aligned with the port of the connecting pipe 306. After alignment, the movable sleeve 305 with the magnet 311 is attracted by the magnetic material at the end of the connecting pipe 306, pulling the movable sleeve 305 out and connecting it with the connecting pipe 306. At this time, the external circulation air path can be opened. When in use, after the fan 312 blows air into the connecting pipe 306, the outside air enters the air supply channel 104 through the installation pipe 304 and the connecting pipe 306 under the action of the fan 312. The airflow will flow into the connecting cavity 106 inside the fixed sleeve 105 through the corresponding air supply channel 104, and then be guided to other air supply channels 104. Finally, it completes active heat dissipation through other installation pipes 304 and the connecting pipe 306 discharge device, avoiding the cable 100 from aging due to long-term high temperature operation and effectively improving the service life of the cable 100.

[0046] During the external circulation process, one set of mounting pipes 304 and movable sleeves 305 are connected to the connecting pipe 306. Mounting pipe 304 serves as the air inlet. During intake, air is filtered through filter membrane 313. Filter membrane 313 can be a waterproof and breathable membrane, achieving waterproof, breathable, and dustproof effects, ensuring the cleanliness and dryness of the airflow entering the cable 100 and preventing dust and moisture accumulation inside the cable 100 that could cause insulation problems. The remaining mounting pipes 304 and movable sleeves 305 serve as air outlets. Airflow from the air delivery channel 104 is discharged from the inside of the other filter membranes 313. During each external circulation, the rotating housing 303 is driven to rotate by a preset angle, causing multiple sets of mounting pipes 304 and movable sleeves 305 to alternately serve as air inlets and outlets, allowing filter membranes 313 at different positions to filter the air intake in turn. Meanwhile, during the rotation process, the filter membrane 313 that was previously used to filter the air intake is switched to the air outlet position. The reverse airflow can wash away the dust and impurities accumulated on the surface of the filter membrane 313, realizing the self-cleaning of the filter membrane 313, avoiding clogging caused by long-term use of the filter membrane 313, ensuring the air permeability and heat dissipation effect, effectively extending the service life of the filter membrane 313, and reducing the maintenance frequency.

[0047] If it is necessary to switch to the internal circulation mode, rotate the housing 303 to align the movable sleeve 308 with the connecting pipe 306. The movable sleeve 308 is attracted and extends out to connect with the connecting pipe 306, thus opening the internal circulation air path. The fan 312 pushes air into one of the air supply channels 104, and then through the connecting cavity 106 inside the fixed sleeve 105 to enter the other air supply channels 104. Then, through the other connecting pipes 306, the air enters the corresponding movable sleeve 308 and the mounting tube 307. The multiple mounting tubes 307 and movable tubes are connected to the hollow ring 309 through the connecting pipe 310, so that the air can flow in the closed internal circulation loop. After being heated by the heating ring 108, the overall temperature of the cable 100 is increased, ensuring the flexibility of the cable 100 at low temperatures. No cold air from the outside is introduced during the process, which can more efficiently complete the overall heating of the cable 100, reduce heat waste, and improve the heating speed in low temperature environments.

[0048] In one possible implementation, the protective sleeve 201 is at least partially made of a prior art thermochromic material that changes color when the temperature exceeds a preset threshold to indicate an abnormal temperature region of the cable 100 body.

[0049] In this embodiment of the invention, when the cable 100 experiences abnormal temperature rise due to insulation aging or poor contact of the conductor 103, the thermochromic protective sleeve 201 at the corresponding location will change color due to the temperature exceeding the threshold. Users can intuitively and quickly locate the abnormal location without the need to use special testing equipment to check section by section, which facilitates quick maintenance and repair and improves the efficiency of fault diagnosis.

[0050] In one possible implementation, a temperature sensor 107 is detachably mounted on the retaining sleeve 105.

[0051] In this embodiment of the invention, the temperature sensor 107 can collect the temperature of the airflow within the connecting cavity 106 of the fixed sleeve 105 in real time. Once the airflow temperature is detected to exceed a preset safety threshold, the external circulation cooling mode will be automatically activated for active heat dissipation; conversely, if the airflow temperature is detected to be below a preset low temperature threshold, the internal circulation heating mode will be automatically activated to heat the inside of the cable 100. This allows for automatic switching of the circulation mode under different temperature conditions without manual intervention, improving the automation level and environmental adaptability of the device. It should also be noted that the temperature sensor 107, motor 316, and fan 312 are all electrically connected to the main control board of the charging pile via wires, and their operation can be directly controlled by the main control board of the charging pile.

[0052] In one possible implementation, a spring is fitted on the outer side of the movable sleeve 305, with one end of the spring fixedly connected to the end of the movable sleeve 305 and the other end of the spring fixedly connected to the inner wall of the rotating housing 303; a spring is fitted on the outer side of the movable sleeve 308, with one end of the spring fixedly connected to the end of the movable sleeve 308 and the other end of the spring fixedly connected to the inner wall of the rotating housing 303.

[0053] In this embodiment of the invention, when the rotating housing 303 rotates, movable sleeve 1 305 and movable sleeve 2 308 move towards the center of the rotating housing 303 under the action of magnetic force, and fit into contact with the connecting tube 306 for stable connection. When the rotating housing 303 rotates and becomes misaligned, the magnetic block 311 moves away from the connecting tube 306, the magnetic force disappears, and springs 1 and 2 pull the corresponding movable sleeves to reset, disconnecting the connection. This does not hinder the normal rotation of the rotating housing 303, ensuring a smooth mode switching process and preventing jamming or misalignment, thus improving the stability of the structure's operation. In addition, during the process of resetting movable sleeve 1 305 by spring 1, movable sleeve 1 305 will collide with the inner wall of the rotating housing 303, causing slight vibration, which in turn causes the filter membrane 313 to vibrate. This helps to remove dust accumulated on the outside of the filter membrane 313, further enhancing the self-cleaning ability of the filter membrane 313.

[0054] In one possible implementation, the end of the mounting tube 304 extending to the outside of the rotating housing 303 is detachably fitted with a hollow end cap, and the filter membrane 313 is disposed inside the end cap.

[0055] In this embodiment of the invention, the end cap is designed to be detachable, which allows the filter membrane 313 to be replaced separately after it ages or its self-cleaning effect fails to meet the usage requirements, without having to disassemble the entire cable structure, thus reducing the difficulty and cost of maintenance and replacement.

[0056] In this invention, an armor layer is fixed between the outer sheath 101 and the filler 102 of the cable 100. The conductor 103 can be made of copper or aluminum. An insulation layer of cross-linked polyethylene material is also arranged on the outside of the conductor 103. This part is a known structure of the cable 100. The applicant will not elaborate on the detailed structural principle.

[0057] This invention encompasses any substitutions, modifications, equivalent methods, and solutions made within the spirit and scope of this invention. To provide the public with a thorough understanding of this invention, specific details are described in detail in the preferred embodiments, while those skilled in the art will fully understand the invention even without these details. Furthermore, to avoid unnecessary misunderstanding of the essence of this invention, well-known methods, processes, procedures, components, and circuits are not described in detail.

[0058] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the embodiments of the present invention, and are not intended to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention. Any changes or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the protection scope of the present invention.

Claims

1. A high-power power cable for new energy vehicles that is resistant to high-voltage cyclic bending, characterized in that, include: The cable body, protective components, and thermal circulation components electrically connected to the charging gun; The cable body includes an outer sheath and a conductor. The conductor is disposed inside the outer sheath, and the inner cavity of the outer sheath is filled with a filler to maintain the cable body in a cylindrical shape. The protective assembly includes multiple protective sleeves fitted onto the cable body, with two connecting components movably hinged between two adjacent protective sleeves. The protective assembly is used to limit the bending position and bending range of the cable body. The thermal circulation assembly includes an air delivery channel formed inside the filling material, and a heating ring is provided inside the air delivery channel. The thermal circulation assembly also includes an external circulation pipe group and an internal circulation pipe group. The air delivery channel can be selectively connected to one of the external circulation pipe group and the internal circulation pipe group.

2. The high-power power cable for new energy vehicles resistant to high-voltage cyclic bending as described in claim 1, characterized in that, The protective sleeve is formed by splicing together multiple collar units. Each collar unit includes a central ring, and multiple protrusions are evenly fixed on the two side walls of the central ring. Two adjacent collar units are staggered so that the protrusions of one unit can be movably inserted into the gap between two adjacent protrusions of the other unit. Each of the multiple protrusions on one side of the collar unit has a movable groove, and a fixing rod is fixed between adjacent protrusions on the other side. Two adjacent collar units are flexibly connected to each other by the movable engagement of the fixing rod and the movable groove.

3. The high-power power cable for new energy vehicles resistant to high-voltage cyclic bending as described in claim 1, characterized in that, The connecting assembly includes two mounting seats, which are rotatably mounted on the collar units of two adjacent protective sleeves. Specifically, the mounting seats are located on the outer side wall of the middle ring of the collar unit. The mounting seats have a U-shaped structure, and mounting grooves are provided on the inner walls of both sides of the mounting seats. A ball joint is movably mounted in the middle of the mounting groove. A universal joint is movably connected between the two corresponding ball joints on the two adjacent protective sleeves.

4. The high-power power cable for new energy vehicles resistant to high-voltage cyclic bending according to claim 1, characterized in that, The protective sleeve is at least partially made of a thermochromic material that changes color when the temperature exceeds a preset threshold to indicate abnormal temperature areas of the cable body.

5. The high-power power cable for new energy vehicles resistant to high-voltage cyclic bending according to claim 1, characterized in that, The cable body is fixed with a fixed sleeve at the end away from the charging gun. The conductor inside the cable body passes through the fixed sleeve and is electrically connected to the power supply equipment. The fixed sleeve is provided with a connecting cavity, which is used to connect the ends of multiple gas delivery channels.

6. The high-power power cable for new energy vehicles resistant to high-voltage cyclic bending according to claim 5, characterized in that, A temperature sensor is detachably mounted on the fixed sleeve.

7. The high-power power cable for new energy vehicles resistant to high-voltage cyclic bending according to claim 1, characterized in that, A fixing tube is fixed to one end of the cable body near the charging gun. A circular fixing plate is fixed to the outer wall of the fixing tube. A rotating housing is rotatably installed on the side of the fixing plate. The outer circulation pipe assembly and the inner circulation pipe assembly are arranged on the inner wall of the rotating housing. The external circulation pipe assembly includes multiple mounting pipes evenly distributed on the rotating housing. One end of the mounting pipe facing the center of the rotating housing is sealed and slidably fitted with a movable sleeve. A magnetic block is fixed at the end of the movable sleeve. The other end of the mounting pipe extends through to the outside of the rotating housing. A filter membrane is provided on the end of the mounting pipe. The internal circulation pipe assembly includes multiple mounting pipes 2, which are respectively arranged in the middle of two adjacent mounting pipes 1. The end of the mounting pipe 2 facing the center of the rotating housing is sealed and slidably fitted with a movable sleeve 2. A hollow ring is fixed on the inner wall of the rotating housing. Each mounting pipe 2 is connected to the inner cavity of the hollow ring by a connecting pipe. Multiple L-shaped connecting pipes are fixed on the fixed pipe. One end of the connecting pipe is fixedly connected to the port of the gas transmission channel, and the other end of the connecting pipe faces the outer circulation pipe group and the inner circulation pipe group; a fan is installed inside one of the connecting pipes.

8. The high-power power cable for new energy vehicles resistant to high-voltage cyclic bending according to claim 7, characterized in that, A motor is fixed to the side wall of the fixed plate, and a gear is fixed to the output end of the motor. A gear ring is provided on the rotating housing, and the gear ring meshes with the gear. Through the meshing of the gear and the gear ring, the rotating housing is driven to rotate around the outer circumference of the fixed plate.

9. The high-power power cable for new energy vehicles resistant to high-voltage cyclic bending according to claim 7, characterized in that, A spring is fitted on the outer side of the movable sleeve, one end of the spring is fixedly connected to the end of the movable sleeve, and the other end of the spring is fixedly connected to the inner wall of the rotating housing. A second spring is fitted on the outer side of the second movable sleeve. One end of the second spring is fixedly connected to the end of the second movable sleeve, and the other end of the second spring is fixedly connected to the inner wall of the rotating housing.

10. The high-power power cable for new energy vehicles resistant to high-voltage cyclic bending according to claim 7, characterized in that, The end of the mounting tube extending to the outside of the rotating housing is detachably fitted with a hollow end cap, and the filter membrane is disposed inside the end cap.

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