Liquid-Cooled Charging Gun Quick-Change Terminals for Fast Repair
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing charging connector replacement process for new energy vehicles is wasteful, time-consuming, costly, and poses safety hazards due to the need for complete replacement of the charging connector and wiring harness, which is inefficient and requires high technical expertise.
Innovation Solution
A quick-change structure for a liquid-cooled charging gun featuring a detachable quick-change terminal and connector head assembly, allowing for rapid replacement of worn-out terminals using special tools without disconnecting the wiring harness, combined with an integrated cooling system for effective maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire charging connector is replaced, then reliability is improved, but loss of time and loss of substance increase
Solution Approach 1:
The charging connector is divided into modular components: the terminal contact reed that can be replaced independently, the wiring harness that remains connected, and the housing that provides structural support. This segmentation allows only the worn terminal to be replaced rather than the entire connector assembly, reducing replacement time from hours to minutes while maintaining reliability.
Solution Approach 2:
The terminal contact reed is designed with dynamic replacement capability through spring-loaded contacts and removable terminal blocks. This allows the terminal to be quickly detached and reattached without permanently fixing it, enabling rapid maintenance while ensuring reliable electrical connection during normal operation.
2Reliability
If the entire charging connector is replaced, then reliability is improved, but loss of substance increases
Solution Approach 1:
The charging connector is divided into modular components: the terminal contact reed that can be replaced independently, the wiring harness that remains connected, and the housing that provides structural support. This segmentation allows only the worn terminal to be replaced rather than the entire connector assembly, reducing material waste while maintaining reliability.
Solution Approach 2:
The terminal contact reed is designed as a replaceable component that can be discarded when worn, while the valuable wiring harness and housing are recovered and retained for continued use. This selective replacement minimizes material waste and reduces maintenance costs.
3Ease of repair
If the wiring harness is disconnected and reconnected, then replacement is completed, but ease of operation deteriorates and safety risks increase
Solution Approach 1:
The charging connector is divided into modular components allowing the terminal to be replaced independently without disconnecting the wiring harness. The terminal blocks are designed with quick-release mechanisms that enable tool-free or minimal-tool replacement, significantly improving ease of operation while maintaining repair effectiveness.
Data Source
AI summary
A quick-change structure for liquid-cooled charging gun, comprises a charging connector main assembly; one side of the charging connector main assembly is fixedly connected with a terminal fixing assembly, and a detachable quick-change terminal is arranged inside the terminal fixing assembly; the front side of the charging connector main assembly is provided with a detachable quick-change gun connector head assembly. The detachable structure realizes effective saving of excessive maintenance costs, labour-hours and material costs. Worn out terminals can be completely replaced within a few minutes after the power is confirmed cut off, and no other actions are required on the charging connector end or harness end. Merely using special tools to disassemble the terminal that needs to be replaced, reassembling and resetting, the quick replacement of wearing parts can be done. Maintenance costs and technical ability requirements for maintenance and replacement are lowered, and rapid replacement and maintenance is realized.