NewNew Products
ProductsConnector and Cable for EV Quick Charger

1.

INTRODUCTION

tive feeling without complicated lever operations
because of a push-on method. In an insert case,push-in during grasping a grip; and in a releasecase, pull the grip while pushing a release button.
The very simple operation has a valuable merit(Figure 2)
Emergency lock releasedevice(Remove cover-lid byforce to operate)

Release button(Pops out at fit-in finish and push
into at releasing)

Grip Case latching(Pops out and lockinto inlet)

Fit-in checkview(Light green)

GripLED lamp
(Light up whilecharging)
Connector part
(Connector part
uncovers at fit-in)

Inlet inspection slider(Slides along insert
into inlet)

Figure 1

Connector construction.

Insertion state

Release state
Just push into

Nowadays, the reduction of the greenhouse gas is mandatory in order to preserve global environment. The transport sector occupies approx.50% of the internal total CO2emission amount. And the CO2 emission amount fromautomobiles occupies approx.90% of the transport sector.
Countermeasures to reduce CO2 emission are indispensable in automotive-related industries.
EVs (Electric Vehicles) use electrical motors for its driving source, therefore the CO2 emission amount including
the charge power of EVs is estimated at approx.1/4 of theamount of the gasoline cars.(JHFC: Japan Hydrogen &Fuel Cell Demonstration Project report).
And so EVs are expected to become a big asset in thereduction of the CO2 emission in the transport sector. On
the other hand, EVs’ battery charge during driving
decreases and approaches run-out called “power out”.
Drivers’ worries about battery remaining charge have tobe addressed. Therefore it is very important to install aninfrastructure of EV quick chargers, where in public places EVs’ drivers can charge in short time.
From above backgrounds, electric power companies
and automotive companies started up together theCHAdeMo Association, that is, an industrial association
for the promotion of the building of an infrastructure of EV
quick chargers which are going to become popular year
after year.
Furukawa Electric Co., Ltd. (FEC) participates in theCHAdeMo Association as a regular member and has
developed the connector and the cable for EV quick chargers and expected for its wide applications in near future.

insertion

ReleasePush

2.

CONSTRUCTION
Just pull the grip
while pressing therelease button.

FEC has developed the connectors for insert into EVs’
outlet called inlet and its lead cable to connect with EV
quick chargers.
2.1 Connector
The specifications of connectors FEC has developed arebased on the recommendations of the CHAdeMo
Association standards and are also available for EVs soldpresently from local automotive manufacturers.
Figure 1 illustrates the connector FEC has developedand its characteristic is shown below.
(1) Intuitive operation
It is easy to understand the operation with an intui-Figure 2

Operation method.

(2) Low insert force
In order to reduce the charging force operation irrespective of age or sex, lever devices are stored
inside the connector so that a large insert force canbe gained from a small actuating force. A connector
with a small insert actuating force is regarded as thetop-class lightness in the industries.

Furukawa Review, No. 41

20129Connector and Cable for EV Quick Charger(3) Safety countermeasure
In a quick charge case a large current above 100 ADC flows. When a connector is not inserted perfectly, a dangerous condition may happen due to aleaking current.
A micro-switch for the inspection of a connection
condition is set inside the connector. In a semi-insert
case, it is impossible to charge. The adoption of arelease button lock mechanism prevents to release
the connector incidentally during charge by meansof electromagnetic solenoid, therefore, even if therelease button were pushed during charge, the control circuit would cut automatically and the charging
stops with a fail safe mechanism.
(4) Superior strength
In order not to destroy the connector under a treadpressure of 2 tons weight vehicles, a metal reinforcement is partially used as armors in an inner andan outer side of the connector. And in a non-insert
condition when the connector is dropped, the outercase can guard the connector head part from thedamage.
(5) Forced release mechanism
After insert the connector into the inlet, even if anemergency happened and the connector cannot
release from the inlet, it would be able to release theconnector by force by operating the emergency lockrelease device with available tools.
2.2 Cable
A cable for EV quick chargers is a complex cable comprised of a power line, a communication line and an earthline. The cable needs safety and ease of operation for asuperior handling property by typical urban drivers. The
cable, FEC has developed, possesses a cab-tire cable
construction which had a lot of application in power supply cables of moving bodies. A high flexibility has already

Table 13.

CONCLUSION

The connector and the cable for EV quick charger that
FEC has developed are a possible product to solve a difficult and complicated operation that EV drivers feel during
the charge operation.
Next, FEC and its groups intend to promote wide applications helped by the advantages of their proper technology for the battery charger infrastructure-related markets.
For more information, please contact:
Engineering Department Energy-Backcast Team
Energy Division
Energy-Industrial Products Company
Furukawa Electric Co., Ltd.
TEL: +81-45-311-1736 FAX: +81-45-311-1850

Sectional view and construction of the 6600 V XLPE power cable.

Sectional viewTable 2

been gained by a material composition and with a proper
design, as shown below.
①Smaller diameter wires of 0.16 mmΦ are used in comparison with available wires of 0.45 mmΦ for cabtire
cables.
②A high flexible soft vinyl material that FEC has developed is applied as an insulation and a sheath.
③The best twisting mode of a power wire and a communication wire is chosen.
The cable satisfies a 600 V vinyl-insulated vinyl-sheathcabtire cable of JIS C 3312, and possesses the required
properties for low-voltage cables.
And a flexibility, a twist-fatigue and an impact-resistanceproperties which are important items from users’ points
are proven superior in each test of these properties.
Table 2 shows the cable properties.

Wire type

Wire core no.×Cross sectional area Finish diameter

Weight2

Communication line

1 pair×0.75 mm

Power supply line

2 cores×34 mm

Communication line

7 cores×0.75 mm

2Approx.32 mm

Approx.1400 g/m

2

Cable characteristics.

Performance evaluation Items
Conductor resistance (20℃)
Insulation resistance (20℃)
Withstand voltage

Wire type
Performance of the developed product Testing standard
2
Power line（34 mm ）Below 0.566 Ω/km
2
Communication line（0.75 mm ） Below 25.9 Ω/km
※Power line（34 mm2）
Above 50 MΩkm
JIS C 3312
2
Communication line（0.75 mm ） Above 30 MΩkm
No failure at 3000 V/1 min.

※600 V vinyl-insulated vinyl-sheath cabtire cable.

Furukawa Review, No. 41

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