New energy vehicles

Connectors play a crucial role in new energy chargers and are the core components for achieving power transmission, signal interaction and safety guarantee. Its function can be analyzed in detail from multiple dimensions:

I. Core Function: The "Bridge" for Electrical Energy Transmission

The core task of a new energy charger is to efficiently transfer the electrical energy from the power grid or energy storage devices to the batteries of electric vehicles (or other new energy devices), and the connector is the physical carrier of this process:

Low-loss conduction: By using materials with high electrical conductivity (such as copper alloys) and optimizing contact design, the resistance loss during current transmission is reduced to ensure charging efficiency (especially in high-power fast charging scenarios, reducing heat generation is crucial).
Adapt to power requirements: According to the power of the charger (such as 220V low power for household use and 380V high voltage and high power for public fast charging stations), the connector needs to match the corresponding current and voltage specifications. For example, the DC fast charging connector needs to withstand hundreds of amperes of current and hundreds of volts of voltage.

Ii. Safety Assurance: The "Protective Shield" During the Charging Process

New energy charging involves high voltage and large current. Safety is the top priority, and the design of connectors directly affects safety performance.

Anti-electric shock protection: By means of insulating housing and anti-mis-touch structures (such as mechanical interlocks between plugs and sockets), it prevents users or foreign objects from coming into contact with conductive components.
Overload and short circuit protection: Some connectors are equipped with built-in fuses or sensors that trigger protection mechanisms when the current is abnormal, working in conjunction with the circuit protection of the charger body to prevent equipment damage or fire.
Environmental adaptability: It features water resistance (such as IP65/IP67 ratings), dust resistance, resistance to high and low temperatures (-30℃ to 85℃), and vibration resistance. It is suitable for complex environments like outdoors and garages, preventing short circuits caused by water ingress or dust.
Electromagnetic compatibility (EMC) : Reduce the electromagnetic radiation generated during charging to prevent interference with vehicles or surrounding electronic devices, while resisting external electromagnetic interference to ensure charging stability.

Iii. Signal Interaction: The "Nerve Center" of Intelligent Charging

Modern new energy chargers (especially on-board chargers OBC and DC fast charging piles) rely on connectors to achieve information communication between devices and support intelligent charging

Identity recognition: The signal pins of the connector can transmit the identity information of the vehicle and the charger (such as vehicle model, battery status), ensuring that the charger matches the vehicle's charging protocol (such as national standard GB/T, European standard CCS, American standard SAE J1772, etc.).
Status feedback: Real-time transmission of battery voltage, current, temperature and other data. The charger dynamically adjusts the output power based on this information (for example, reducing the current when the battery is nearly fully charged) to avoid overcharging.
Control command transmission: The vehicle can send commands such as "Start/stop charging" and "Adjust power" to the charger through the connector, achieving two-way interaction and enhancing the intelligence and safety of charging.

Iv. Mechanical Compatibility: The "Executor" of Convenience and Durability

Convenient plugging and unplugging: Through an optimized plugging and unplugging structure (such as labor-saving clips and guiding design), users can easily connect or disconnect the charger from the vehicle, while ensuring the stability of the connection (avoiding accidental detachment during charging).
Durability guarantee: The connector needs to withstand frequent plugging and unplugging (thousands or even tens of thousands of times). Its contact parts are made of wear-resistant and anti-oxidation materials (such as gold or silver plating), and the housing is made of high-strength plastic or metal to extend its service life.

V. Standardization and Compatibility: The "Universal Language" for Industry Interoperability

Vehicles and chargers of different brands need to be compatible through a unified connector standard. The standardization of connector specifications is the foundation of industry development