preface
The popularity of new energy vehicles is inseparable from its low-carbon environmental protection, energy-saving and quiet advantages. Just as gasoline cars need to be refueled with fuel guns, new energy vehicles use charging guns to charge cars and replenish energy. Cars belong to large commodities, new energy vehicle users, the quality of charging guns are very important, for this reason, the charging head network has disassembled several brands of charging gun products.
Charging head network recently got a Zeesung Zhichong's 2860W portable AC charging gun, with IP67 waterproof rating, support 13A charging current, with three indicator lights to indicate the working status, simple and reliable. The following charging head network disassembles this charging gun to see how the internal design is.
Zhichong 2860W AC charging gun unboxed
The charging gun is packed in a tote bag for easy storage and carrying on the bus.
Charging gun at a glance, in addition to the charging gun head, portable charging box, is a thick cable connecting each other, plug plug sleeve with plastic shell protection, below we come to learn more.
The plug adopts the design of water droplet shape, and the inside side is designed with ground wire, fire wire and zero line logo next to the plug, and the specification is 16A 250V~.
The diameter of the measured cable was 10.75mm.
There is a rubber ring fixed protection at the junction of the cable and the charging case.
A portable charging case is added between the cables, the shell is frosted and anti-fingerprint, the top raised edge is tilted, the top surface is pasted with a white card similar to dumbbells, in addition to the logo, name and other designs, there are three status indicators on the edge, corresponding to power, charging and fault.
The bottom housing is printed with the indicator status chart, user instructions and main parameters
Model: EV-ZC-1CCPD16A-15
Input/output voltage: AC 220V 50Hz
Maximum output current: 13A
Protection class: IP67 (control box only)
Operating temperature: -30°C~+50°C
One end is also specially designed for wall fixing.
The main shell of the charging tip is white, the surface is frosted, and the shape is ergonomically designed to enhance the user's experience
The product name, model number and current voltage parameters (16A 250V AC) are printed on the grip.
The top features a protruding tooth shaped trip button.
Many screw holes can be seen on the other side.
The tip end of the gun is covered with a rubber sleeve to prevent dust and moisture and oxidation.
The fixed snap-up is close-up and the metal material is not easy to break.
Close-up at the end, with seven round holes and metal columns in the center, fits the charging port design of domestic electric vehicles.
Zhichong 2860W AC charging gun disassembly
Once you have a basic understanding of this charger, let's disassemble it and see how it is designed.
Tear open the sticker on the back cover of the charging gun and hide the fixing screws underneath.
Unscrew the fixing screws, open the charging gun housing, and have a cable connected to the panel indicator board to indicate the working status of the charging gun.
The interior of the housing fixing column is fixed by injection molded copper nuts, which is more secure and is not easy to damage when dropped.
The small plate is screwed to the inside of the housing.
Close-up of the input terminals, screwed to the terminals.
Wire cold press terminal fixed.
Close-up of the input terminals, green terminals on the right to secure the auxiliary cable.
Unscrew the screws that hold the terminals and remove the charging gun control panel.
Connect the cables for the panel LEDs.
Solder power INDICATOR, charging indicator, and fault indicator on the small board.
The front of the control board is at a glance, the two relays on the right side are used for vehicle charging output control, and the middle and lower are current transformers and zero-sequence current transformers for charging current monitoring and leakage protection. Above the middle is the internal switching power supply circuit of the charging gun, and below the right is the input common mode filter circuit.
The high-current trace on the back of the control board exposes copper and tin to increase the cross-sectional area. There are multiple chips on the back for functional control, and the back of the control panel is coated with three anti-paint moisture protection.
The switching power supply on the side of the protection circuit for the charging gun is welded using a small board.
There is a small common-mode inductor at the input.
Two Y capacitors at the input.
Close-up of the common mode inductance at the input, two wires built-in insulation plate and glue fixed. The bottom of the inductor is fixed with white glue.
X capacitor with 0.47μF capacity.
Two current transformers for zero-sequence current sensing and charge current sensing, respectively. The transformer that crosses the two copper wires is zero-sequence current detection for leakage protection function, and the single copper wire is current detection for protection during charging.
The current transformer comes from Zhicheng Electrical Measurement.
Two relays controlling the charging output are from HF161F-W, with a coil voltage of 12V, using silver tin oxide contacts with a contact capacity of 26A and 250VAC.
Close-up of the output terminals.
The power module is close-up, using an integrated power chip, a large area of glue reinforcement, to avoid damage when the charging gun accidentally falls.
The X capacitance at the input is 0.1μF.
Close-up of the common-mode inductance.
10D471K varistors for input overvoltage protection.
The input filter capacitance of the power module is 10μF 400V from Fongbin.
The switching power supply main control chip is from ST St. Electronics, model VIPER27L, built-in 800V switch tube, switching frequency 60kHz.
The supply capacitor is from the mid-element, 47μF 16V.
The transformer adopts EE16 core.
817 optocoupler for feedback output voltage.
The output filter capacitor is 16V 330μF.
The charging gun has a built-in ST ST STM8S005K6 microcontroller for the control of the charge gun protection function.
The use of Fudan micro FM2147 dedicated chip for charging gun leakage protection, with zero sequence current transformer to achieve.
The Wango V9261F single-phase power metering chip is used for charging power metering.
ON ON OnSenmei 1175VG screen printing, the actual model is NCV1117-5.0, three-terminal linear voltage regulator chip, used for charging gun internal chip power supply.
TI Texas Instruments LM2904 Dual Op Amp for Signal Acquisition amplification.
TI Texas Instruments LM2903 dual voltage comparator for protection function sensing.
Below is the dismantling of the charging gun body.
First unscrew the screws that hold the housing and open the charging gun housing.
The wires are connected directly to the charging gun plug.
The cable is pressed and secured using a sheet of metal.
Both the housing and screws are sealed with rubber seals to prevent water ingress.
Push button switch to detect if the charging gun is inserted into place and to detect the pulling action.
Hook reset spring close-up.
There is a temperature safe in the line of fire, which is fixed with a heat shrinkable tube.
Cut the heat shrinkable tube, the temperature safety action temperature is 90 ° C, detect the terminal temperature rise, and notify the vehicle to cut off the charging input when the temperature is too high.
There is also a heat shrink tubing on the head.
Cut open the heat shrink tubing and inside are two resistors.
The resistors are 680Ω and 2.7KΩ respectively for signal level divider.
All disassembled, let's take a family portrait.
Charging head net disassembly summary
Zeesung Zhichong's charging gun has a relatively simple function and only provides a basic charging function box status display. Terminals are used inside the control box to connect the wires, which is convenient for replacing wires of different lengths, and also facilitates assembly and production. A separate power supply board is used inside the charging gun to power the control circuitry.
The charging gun uses ST STM8S005K6 microcontroller for whole machine control and status acquisition, Fudan Micro FM2147 for leakage protection during charging, Wangao V9261F for charging power metering, and Texas Instruments LM2903 and LM2904 for signal acquisition and protection functions.