𐄀 Technology Connection to Future
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With the development of new energy vehicles, range and charging time has become the two key factors restricting the development of new energy vehicles, and with the increase of range, battery capacity, charging time will be extended, in order to improve the practicability of new energy vehicles in society and convenience in daily use, high-power charging will be an effective way to shorten the charging time. This type of efficient charging connectors will be an appropriate choice.
| GB Liquid (oil)- coold High-power DCCharging Connector Technical Specification | |||||||
| Technical parameters of the charging connector | |||||||
Electrical parameters | Port definition | DC± | PE | A± | CC1 | CC2 | S± |
Wiring specification (mm²) | 30 | 6 | 1.5 | 0.5 | 0.5 | 0.5 | |
Contact Terminal Diameter (mm) | Φ12 | Φ6 | Φ3 | Φ3 | Φ3 | Φ3 | |
Rated Operating Voltage (DC) | 1000V | 0—30V | 0—30V | 0—30V | 0—30V | 0—30V | |
rated current | 100A(when the liquid cooling system is not working) | / | 10A | 2A | 2A | 2A | |
Maximum continuous working current | 600A (line length and thermal management capacity) | ||||||
outside diameter of cable | φ 30mm ± 0.6 (ground wire 6mm², auxiliary power supply 1.5mm²) | ||||||
The weight of the connector | <1.1 Kg (without cable) | ||||||
insulation resistance | 2000 MΩ between DC positive and negative terminal and PE terminal (test voltage 1000V D C) | ||||||
Pressure withstand (50Hz, AC) | Test after plug wiring: ① Resistance voltage between DC + and DC-4500 V DC 1min; ② DC +, DC-and PE, S +, S +, A +, A-resistance voltage 1500 V DC 1min; ③ PE, resistance voltage of 1500V D C 1min between S +, S-, A + and A-; ④ S +, S-, CC1, A +, A-two resistance voltage of 1500V D C 1min; | ||||||
Note: The outer diameter and the core area of the cable can be designed and customized according to the actual needs of customers | |||||||
Mechanical properties | Service life: | 10000 times | |||||
Plug and pull force: | 120N | ||||||
Lock-in force: | 200N | ||||||
Environmental parameters | Level of protection before insertion: | IP54 | |||||
| Grade of protection after insertion: | IP55 | ||||||
| High-voltage electrical part: | IP67 | ||||||
Ambient temperature: | -30℃ - - + 50℃ | ||||||
| Flame retardant grade of insulation materials: | UL94 V-0 | ||||||
Materials | Housing: | engineering plastics (temperature resistant PA66 or temperature resistant PC) | |||||
| Terminal: | copper, surface silver-plated | ||||||
Seal parts: | silicone rubber | ||||||
Appearance of the charging connector |
Figure 1.1 Appearance of interface liquid (oil) cooled DC charging connector (GB / T 20234-2023) | ||||||
Interface definition | The following figure shows the diagram of the power copper row interface, signal wire harness interface and cooling line interface between the connector line and the pile end. The following structure is generally customized design. | ||||||
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Liquid medium cooling unit (HPC cooling module assembly) | |||||||
| Technical parameters | Table 1: Technical parameters table | ||||||
size | 435×155×410(mm) | Heat dissipation power | 3.0KW@4L/min .700m3/h | ||||
input voltage | DC12V | power | ≤200W | ||||
cooling medium | Dimethyl silicone oil Di-tert-butyl-p-methylphenol TF8016 Fuchs Coolant Shell E4 (-40~85℃) | Cooling flow | 4L/min@450Kpa | ||||
Water supply pressure | 0.6Mpa | working pressure | 0~0.7MPa | ||||
working temperature | -40℃-50℃ | Expansion pot volume | 1.5 L | ||||
noise | ≤60dB（A） | levels of protection | IP 68 | ||||
weight | 7Kg | communication mode | Based on the Modbus 485 / 232 | ||||
control method | full-automation | life span | 25000h | ||||
Definition of the wiring pin | Table 2 Definitions of the wiring pins | ||||||
order number | name | Cross-sectional area of the wire (mm²) | Terminal model | remarks | |||
| 1 | Signal ground | 0.5 | E0508 | CI | |||
| 2 | A + (485 communication) / 485-A | 0.5 | E0508 | CI | |||
| 3 | A- (485 communication) 485-B | 0.5 | E0508 | CI | |||
| 4 | Fan Enable + | 0.5 | E0508 | Fan power control | |||
| 5 | Fan enabling- | 0.5 | E0508 | Fan power control | |||
| 6 | 12V/24V+ | 1.0 | TVS1.25-4 | Controller power supply | |||
| 7 | GND | 2.5 | TVS2-4 | Controller power supply | |||
| 8 | Pump enabling + | 0.5 | E0508 | Pump power control | |||
| 9 | Pump enabling- | 0.5 | E0508 | Pump power control | |||
| 10 | Pump 12V / 24V + | 1.0 | TVS2-4 | Pump power control | |||
| 11 | Fan: 12V / 24V + | 1.0 | TVS2-4 | Fan power supply | |||
Safety precautions | This product takes the insulating liquid as the cooling medium, if unauthorized replacement may lead to the decline or damage of the sealing structure of the cooling module, or even cause the damage of the connector line. The lid of the expansion pot is filled with cooling medium and opened when necessary. In other cases, the lid is in a tight state to prevent dust, small particles, water and other substances from entering, so as to avoid blockage or safety accidents. It is forbidden to touch the hand in the product work to prevent the fan from injuring the hand. Do not touch the radiator during the product work to prevent scalding. | ||||||
Cleaning and maintenance | Clean up only when the product is not energized. Clean the electrical parts and the remaining parts with a dry cloth. Do not use detergent, water connector, steam connector with corrosive effect for cleaning. Most of the product parts are thermoplastic plastic, do not make the product is impacted by external force, so as not to affect the use.secret During the use of the product, the expansion pot liquid level should be checked regularly to avoid the failure of the liquid level sensor Product damage and safety accidents caused by the alarm. The recommended inspection period is once a quarter. Check the product regularly for leakage. | ||||||
GB Liquid (water)- coold High-power DC Charging Connector Technical Specification | |||||||
Technical parameters of the charging connector | |||||||
Electrical parameters | Port definition | DC± | PE | A± | CC1 | CC2 | S± |
Wiring specification (mm²) | 48 | 6 | 1.5 | 0.5 | 0.5 | 0.5 | |
Contact Terminal Diameter (mm) | Φ12 | Φ6 | Φ3 | Φ3 | Φ3 | Φ3 | |
Rated Operating Voltage (DC) | 1000V | 0—30V | 0—30V | 0—30V | 0—30V | 0—30V | |
Rated current | 125A (when the liquid cooling system is not working) | / | 10A | 2A | 2A | 2A | |
Maximum continuous working current | 500A (line length and thermal management capacity) | ||||||
outside diameter of cable | φ28mm±0.6 | ||||||
The weight of the connector | <1.1 Kg (without cable) | ||||||
insulation resistance | 2000 MΩ between DC positive and negative terminal and PE terminal (test voltage 1000V AC) | ||||||
Pressure withstand (50Hz, AC) | Test after plug wiring: ① Resistance voltage between DC + and DC-4500 V DC 1min; ② DC +, DC-and PE, S +, S +, A +, A-resistance voltage 1500V AC 1min; ③ PE, resistance voltage of 1500V AC 1min between S +, S-, A + and A-; ④ S +, S-, CC1, A +, A-two resistance voltage of 1500V AC 1min; | ||||||
Note: The outer diameter and the core area of the cable can be designed and customized according to the actual needs of customers | |||||||
Mechanical performance | Service life: | 10000 times | |||||
| Plug and pull force: | 120N | ||||||
| Lock-in force: | 200N | ||||||
Enviromental parameter | Level of protection before insertion: | IP54 | |||||
Grade of protection after insertion: | IP55 | ||||||
| High-voltage electrical part: | IP67 | ||||||
| Ambient temperature: | -30℃ - - + 50℃ | ||||||
| Flame retardant grade of insulation materials: | UL94 V-0 | ||||||
Material | Housing: | Engineering plastics (temperature resistant PA66 or temperature resistant PC) | |||||
| Terminal: | copper, surface silver-plated | ||||||
| Seal parts: | silicone rubber | ||||||
Interface definition | The following figure shows the diagram of the power copper row interface, signal wire harness interface and cooling pipeline interface between the connector wire and the pile end. The following structure is generally customized design. | ||||||
Figure 2. Diagram of connector line inlet pile interface (for reference) | |||||||
Liquid medium cooling unit (HPC cooling module assembly) | |||||||
Technical parameters | Table 1. Technical parameters table | ||||||
size | 306×136×358(mm) | Change the heat | 1.6KW（50℃） | ||||
input voltage | DC12V/24V | power | ≤160W | ||||
current | Fan (12V) | Max 9A | |||||
Pump (12V) | Max 7A | ||||||
cooling medium | Antifreeze solution (water + ethylene glycol) | Cooling flow | 0-2.5L/min Adjustable | ||||
Water supply pressure | 6bar | working pressure | 0-6bar | ||||
working temperature | -30℃-50℃ | Expansion pot volume | 1.5 L | ||||
noise | ≤60dB（A） | levels of protection | IP 68 | ||||
weight | 3.5Kg | communication mode | Based on the Modbus 485 / 232 | ||||
| Definition of the wiring pin | Table 2. Definition table of wiring pins | ||||||
No. | Name | Cross-sectional area of the wire (mm²) | Terminal model | remarks | |||
| 1 | Signal ground | 0.5 | E0508 | CI | |||
| 2 | A + (485 communication) / 485-A | 0.5 | E0508 | CI | |||
| 3 | A- (485 communication) 485-B | 0.5 | E0508 | CI | |||
| 4 | Fan Enable + | 0.5 | E0508 | Fan power control | |||
| 5 | Fan enabling- | 0.5 | E0508 | Fan power control | |||
| 6 | 12V/24V+ | 1.0 | TVS1.25-4 | Controller power supply | |||
| 7 | GND | 2.5 | TVS2-4 | Controller power supply | |||
| 8 | Pump enabling + | 0.5 | E0508 | Pump power control | |||
| 9 | Pump enabling- | 0.5 | E0508 | Pump power control | |||
| 10 | Pump 12V / 24V + | 1.0 | TVS2-4 | Pump power control | |||
| 11 | Fan: 12V / 24V + | 1.0 | TVS2-4 | Fan power supply | |||
Liquid medium cooling unit (HPC cooling module assembly)
The HPC cooling module assembly (HPC-CU) is used for intelligent high-power charging (HPC) technology. The heat dissipation power of 3.0KW can bring the charging current up to 600A, while ensuring the safe and stable operation of the combined charging connection system (CCS). The core technology of this product is to provide coolant with appropriate temperature and flow to CCS under full working conditions, so as to ensure that the temperature of CCS relative to the ambient temperature is not more than 50K (ΔTmax = 50K) during charging.
2. Principle
HPC CCS Charging can transport more than 600A charging current, the use of conventional charging technology requires the use of heavy cables or often lead to CCS overheating, in order to facilitate charging operation, intelligent HPC charging technology adopts liquid cooling system, the system HPC cooling module assembly uses environmental protection cooling medium to provide cooled source to CCS, easy to maintain. The cooling medium can simultaneously cool the cable and the DC power terminal of the charging connector.
Charging connector terminal has excellent thermal conductivity, so it can also act as a radiator in the charging process.
A closed loop connecting the HPC cooling module assembly inlet and outlet tube to the CCS outlet tube and inlet tube, The cooling medium is driven by the circulating pump, CCS Transfer of the generated heat to the circulating cooling medium, The cooling medium then transfers the heat to the radiator, The radiator then achieves continuous heat dissipation through an electronic fan blower, In this process, The module collects real-time inlet and outlet liquid temperature through the sensor, Adjust the rotational speed of the pump and fan according to the collected temperature, Realize the real-time adjustment of the heat dissipation power, Put the CCS within a suitable working range, So as to ensure the safety and stability of HPC charging pile.
Figure 1. Schematic diagram of the high-power charging and cooling system
3. Product diagram of high-power charging liquid cooling system (W)
Figure 2. Product diagram of the liquid-cooling system
Automatic control program (standby mode, automatic mode, sleep mode, fault mode, etc.), can prolong the life and save energy.
5. Installation dimensions
Figure 3. Installation dimensions of bottom plate (optional)
Figure 4. Installation dimensions of the bottom plate (customizable)
6. Block diagram of electrical control principle
Figure 5. Schematic block diagram of electrical control
The functions of the controller include: collecting the sensor information, collecting the abnormal fault information, communicating with the charging pile end, and adjusting the pump and fan speed.
1) Collect the sensor information
The temperature and pressure of the inlet fluid and the temperature of the return fluid.
2) Collect the abnormal fault information
Collect fan fault, pump fault, temperature sensor fault, temperature and pressure sensor fault, high temperature, high pressure, low pressure, high level and low level.
3) Charging pile terminal communication
The controller sends the collected normal information and the abnormal information.
For example, receive information about "whether to be charging", "whether to limit current charging", "whether debugging and maintenance", and the temperature value of charging pile collection, etc.
4) Control the fan and the pump
The controller compares the collected current temperature with the set upper temperature limit (such as 90℃) (e.g., the current inlet liquid temperature and the current inlet liquid temperature upper limit), uses the control algorithm to obtain the target speed of the fan and pump, and then adjusts the pump speed and fan speed.
Figure 6. Definition diagram of the wiring pin
7. Matters needing attention
A. Product supplementary description
The above test data do not represent the temperature rise data of all models of liquid-cooled charging connectors, but should be comprehensively considered according to the wire diameter, cable length, the power of the radiator matched by the system and the pump (the flow of coolant circulation) (our company will provide full technical support);
The product conforms to GB / T 20234.1-2023;
Liquid-cooled cable is customized cable, no standard cable, its performance (such as mechanical strength, etc.) can refer to the relevant provisions of GB / T 33594-2017, IEC 62893-4-1 / 2, but temporarily cannot pass the certification;
B. Notes for use
Charging connector coolant is recommended to choose insulating liquid such as Shell E4 and TF8016 Foss coolant;
Unfixed accessories model of the heating management system (such as oil pump, radiator, etc.), conduct comprehensive analysis and experiment for power matching of the accessories according to the customer's current carrying requirements, charging curve, charging connector line length and other requirements;
It is recommended to use the connector line manufacturer to specify the thermal management system (pump, radiator, temperature sensor, control program, etc., integration), and also to provide the cooling system matching and selection support;
The rated working pressure of the connector line is 5Bar, meeting the minimum flow rate of thermal management is 4L / min;
Other cooling medium other than the coolant specified by the manufacturer is prohibited, and the mixing of the cooling medium is prohibited.
National standard liquid (water) cooled DC charging connector
1. Product model and interface standard:
The internal model of the product is YGC1352A-EV-P9P-500XL1, and the interface standard of liquid (water) cooled DC charging connector meets the requirements of GB / T 20234.3-2023 standard.
2. Introduction of product advantages
And the product relative to the conventional national standard dc charging connector rated voltage (1000V), the current larger (depending on specific charging strategy, through the 500A, 30 minutes current test), charging power, charging efficiency is higher, can truly solve the new energy vehicles users charging anxiety, the test data 3-5 minutes can supplement the new energy vehicles driving 100 Km electricity.
3. Appearance of the charging connector
Figure 1. Appearance of Yonggui National Standard (GB / T 20234-2015) interface liquid (water) cooled DC charging connector
Liquid medium cooling unit (HPC cooling module assembly)
1. Product Introduction
HPC cooling module assembly (HPC-CU) is used for intelligent high-power charging (HPC) technology. The heat dissipation power is 1.6KW, which enables the charging current to reach 500A, and ensures the safe and stable operation of GB DC charging connector line assembly (referred to as DC charging connector line). The core technology of this product is to provide coolant with appropriate temperature and flow to the DC charging connector under full working conditions, so as to ensure that the temperature of the DC charging connector does not rise more than 50K (ΔTmax = 50K).
2. Principle
HPC DC charging connector line can transfer more than 500A when charging current. Using conventional charging technology needs to use heavy cable or often lead to overheating of DC charging connector line. In order to facilitate charging, intelligent HPC charging technology adopts liquid cooling system. HPC cooling module assembly in this system uses environmentally friendly cooling medium to provide cooled source for DC charging connector line and is easy to maintain.
The cooling medium can simultaneously cool the cable and the DC power terminal of the charging connector. Charging connector terminal has excellent thermal conductivity, so it can also act as a radiator in the charging process. The closed loop is formed by connecting the incoming and outlet pipes with the HPC cooling module assembly and the inlet pipe of the DC charging connector line, The cooling medium is driven by the circulating pump, The DC charging connector line transfers the generated heat to the circulating cooling medium, The cooling medium then transfers the heat to the radiator, The radiator then achieves continuous heat dissipation through an electronic fan blower, In this process, The module collects real-time inlet and outlet liquid temperature through the sensor, Adjust the rotational speed of the pump and fan according to the collected temperature, Realize the real-time adjustment of the heat dissipation power, So that the DC charging connector line is in a suitable working range, So as to ensure the safety and stability of HPC charging pile.
Figure 2. Schematic diagram of the high-power charging and cooling system
Figure 3. Product diagram of the water-cooling system
4. Functional features
⑴ Car standard grade products
Design and development, component selection, experimental verification, manufacturing process and quality control are all developed in accordance with the vehicle specification level IATF16949 system.
⑵ IP68 protection
Fully prevent dust from entering the internal core components, in not more than 1 m deep water immersion, clean can work normally.
⑶ Miniaturization
Lightweight, integrated, and small in size.
⑷ Energy saving
According to the charging condition, the output power of the fan and water pump is automatically adjusted to achieve energy saving.
⑸ Automatization
Automatic control program (standby mode, automatic mode, sleep mode, fault mode, etc.), can prolong the life and save energy.
5. Installation dimensions
Figure 4. Installation dimensions diagram
6. Block diagram of electrical control principle
Figure 5. Block diagram of electrical control principle
The functions of the controller include: collecting the sensor information, collecting the abnormal fault information, communicating with the charging pile end, and adjusting the pump and fan speed.
⑴ Collect the sensor information
The temperature and pressure of the inlet fluid and the temperature of the return fluid.
⑵ Collect abnormal fault information
Collect fan fault, pump fault, temperature sensor fault, temperature and pressure sensor fault, high temperature, high pressure, low pressure, high level and low level.
⑶ Charging pile terminal communication
The controller sends the collected normal information and the abnormal information.
For example, receive information about "whether to be charging", "whether to limit current charging", "whether debugging and maintenance", and the temperature value of charging pile collection, etc.
⑷Control the fan, and the pump
The controller compares the collected current temperature with the set upper temperature limit (such as 90℃) (e. g., the current inlet liquid temperature and the current inlet liquid temperature upper limit), uses the control algorithm to obtain the target speed of the fan and pump, and then adjusts the pump speed and fan speed.
7. Definition of the wiring pin
Figure 6. Definition diagram of the wiring pin
8. Matters needing attention
8.1. Product supplementary description
⑴ High-power liquid-cooled charging connector has no corresponding national and industry standards, so it cannot pass the strong inspection certification;
⑵ Liquid-cooled cable is customized cable, no standard cable, its performance (such as mechanical strength, etc.) can refer to the relevant provisions of GB / T 33594-2017, IEC 62893-4-1 / 2, but can not pass the certification;
⑶ Because there is a cooling pipeline inside the liquid-cooled connector line, the connection fixed structure with the pile end cannot directly follow the cable tightening structure of the conventional DC charging connector line. According to the different shape of the charging pile and the internal electrical design, the connection structure of the connector line and the pile needs to customize the design.
8.2. Notes for use
⑴ Charging connector coolant must be selected vehicle coolant (can be 50% ethylene glycol aqueous solution, but need to use deionized water), it is recommended to purchase through regular channels, prohibit self-blending;
⑵ It is strongly recommended to use the liquid medium cooling device (HPC cooling module assembly) designated by the connector line manufacturer. After selecting the cooling device, the pressure and flow rate should be matched and adjusted. The rated working pressure of the connector line is <1Bar, which can meet the minimum flow rate of 1L / min of thermal management;
⑶ No cooling medium other than the coolant specified by the manufacturer, the mixing of cooling medium, and the cooling system filled with cooling medium such as dimethyl silicone oil.
⑷ Expansion pot lid in the filling cooling medium and open when necessary, the rest of the situation to ensure that in the tight state, to prevent dust, small particles, water and other substances from entering, so as to avoid blockage or safety accidents.
⑸ It is forbidden to touch the product work, to prevent the fan injured hand.
⑹ Do not touch the radiator during the product work to prevent scald.
⑺ Can only when the product is not powered up, use dry cloth to clean electrical parts and other parts, do not use corrosive detergent, water connector, steam connector for cleaning.
⑻ Most of the product parts are thermoplastic, do not make the product is impacted by external forces, so as not to affect the use.
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