Special Issue

Smart Grid

RelatedRelated productproduct

Connector for EV Quick Chargers
1.

INTRODUCTION

With the spread of electric vehicles (EVs), the number of
installation of quick chargers is increasing. As the numberof the feeding operation using connectors for quick chargers is increasing, the improvement points of the connectors are happening. There are increasing needs for theiruser-friendliness and safety.
We have developed a “connector for quick chargers”,
which is easier to use and safer. In this connector, thecustomers’ needs, stated above, and the functions in theformer model which received favorable reviews are combined (Figure 1).

2.

CONSTRUCTION(1) Intuitive operability
The developed connector inherits the good points ofthe former model. On top of that, it adopts the “push-onmethod” in which the operation is intuitive and easy
and also the lever operation is easy.
It features an easy operation: When inserting, holdthe grip and slide it down. When releasing, pull out thegrip, while pushing the release button (Figure 2).
(2) Low insertion force
It succeeded the built-in lever mechanism which canchange a small insertion force to a large one. Its insertability is leading the industry.
(3) Safety measures
Direct-current electricity of equal to or larger than 100 A

Case latch(lock to inlet)

is flowing during quick charge. When electricity is flowing in the state and the connector is inserted incompletely (incomplete mating), a hazardous situation
caused by the arc is predictable. To deal with this problem, a micro switch, which detects the incomplete mating state, is installed in the connector to prevent thecharger from carrying electricity in the incomplete mating state.
In addition, we adopted a mechanism in which therelease button is locked by an electric solenoid whileelectricity is flowing. It prevents the connector fromreleasing accidentally while electricity is flowing. The
fail-safe system, in which electricity stops by shutting
the control circuit, was adopted again in case therelease button is pressed while electricity is flowing.
We enhanced the safety by adding a mechanism inwhich electricity stops when the electric solenoid isjammed with ice, etc.
(4) Superior mechanical strength
The exterior and the interior of the connector are partially equipped with a metal reinforced material as well as
the former model. The reinforced material protects theconnector from breaking even when it is pressed by a 2ton vehicle. Also, the head of the connector is protectedby the outside case all the time regardless of the aftermating and of the after unmating. Thereby, the resistance to the drop impact of the connector wasenhanced.
(5) Release mechanism for abnormal locking
A release mechanism for abnormal locking is used

After Mating
Grip

After Unmating
Just hold grip
and slide down
MatingConnectingpartOutside case

Unmating

Press
Release button

Figure 1 Construction of a connector.

Just pull out
grip, pushingreleasebutton

Figure 2 Operation procedure.

Furukawa Review, No. 43

201341

Connector for EV Quick Chargers

when the connector is firmly fixed to the inlet abnormallyfor any reason. The mechanism was moved from the center of the connector to the grip side to ensure the emergency release operation from the backward of the connector. (A special tool is used for the release operation.)
It also has a safety structure that the connector which
was released forcefully will not be able to be used again(Figure3).

Mating confirmation window

GreenRedLED lamp
(light up during charge)

Emergency release device part
Remove cover atforced release

Figure 4 Mating confirmation window.

(8) Grip
The form of the grip was revised to be easily operated
with gloves in winter.
Figure 3 Release mechanism for abnormal locking.

3.

(6) Mating confirmation window
A new mechanism called a mating confirmation window
was added. When the charge is disabled by the connector’s inner abnormality which can’t be confirmed
from outside, the color of the window which shows thestate of the connector turns red and notify the user ofthe inner abnormality.
Black: Release state
Green: T he connector is normally inserted into the inlet.
Red: C harge is unserviceable. (Electricity must notflow in the connector.)
The LED lamp turns on during charging (Figure 4).
(7) Release button
The material of the release button was changed frommetal to plastic so that the operation can be easier inwinter. Also, the angle of the release button waschanged so that women can press it easily.

Table 1

CONCLUSION

Our company’s connector for quick chargers improved
the problems of the “hardness of the cable” and the “difficulty in operation”, of which the users of electric vehicles
felt during charging. We achieved it by using a cable withgreat flexibility.
The developed connector enhanced the user-friendliness and the safety compared to the existing ones.
We will continue to launch various products in thecharging infrastructure related market by making themost use of the knowhow which the Furukawa Grouppossesses.
For more information, please contact:
Energy Backcast Team
Engineering Department
Energy Division
Energy & Industrial Products Company
TEL: +81-45-311-1736 FAX: +81-45-311-1850

Product specification.

・CHAdeMO standard specification Ver 1.0 conformity
・JEVS G105 (1993) conformity
319

Unit (mm)90
Outline dimensions(release state)

201

Number of position

Power: two positions

Signal: seven positions

Material

Connector: plastic

Net Weight

Connector: approx. 1.6 kg Cable: approx. 1.4 kg/m

Furukawa Review, No. 43201342