Maintenance of the sealing performance of the charging interface of the charger

The charging interface, as a key connection point between electric vehicles and charging equipment, its sealing performance directly affects charging safety, equipment lifespan and user experience. The following provides professional suggestions from aspects such as daily maintenance, regular inspection, and fault handling:

First, daily maintenance precautions

Avoid physical damage

Operating procedures: When plugging or unplugging the charging gun, apply force vertically to avoid diagonal pulling that may cause deformation of the interface or displacement of the sealing ring.

Protective measures: When the vehicle is in motion or parked, ensure that the cover plate of the charging interface is fully closed to prevent foreign objects (such as sand, dust, and branches) from entering.

Environmental selection: Try to charge in a dry environment free of corrosive gases, and avoid long-term exposure of the interface to moisture or acidic or alkaline environments.

Keep the interface clean

Regular cleaning: Use a dry microfiber cloth to wipe the interface surface to remove dust, water stains or oil stains.

Do not use corrosive cleaners: Avoid using solvents such as alcohol and gasoline to prevent damage to the sealing material.

Special scene handling: If the interface is contaminated with mud, sand or salt (such as in a coastal environment), it should be rinsed with clean water and dried immediately, and the sealing ring should be checked for integrity.

Prevent liquid intrusion

Charging in rainy days: Give priority to choosing charging piles with rain shelters or cover the interfaces with waterproof covers. After the charging is completed, immediately close the interface cover plate and lock it.

Waterlogged sections: Avoid driving through water deeper than the charging interface to prevent water from seeping in through the gaps in the cover plate.

Second, regular inspection and maintenance

Check the condition of the sealing ring

Visual inspection: Check the sealing ring for aging, cracking or deformation every three months. If the sealing ring is found to be hardened, sticky or darker in color, it should be replaced in time.

Replacement method: Contact professional maintenance personnel and use the original factory sealing ring for replacement to ensure that the size and material match.

Interface sealing test

Simple test: In a dry environment, gently tap the interface downward and observe if there are any water droplets or foreign objects falling off.

Professional inspection: Send for inspection once a year. Use a gas tightness tester to conduct a pressure test on the interface (for example, the IP67 standard requires no water to enter at a depth of 1 meter for 30 minutes).

Electrical performance test

Insulation resistance test: Use a megohmmeter to measure the insulation resistance between the interface and the vehicle body. The normal value should be greater than 100MΩ. If the value is lower than this, it is necessary to check whether the moisture is caused by the failure of the seal.

Contact resistance detection: Ensure that the contact resistance between the charging gun and the interface is less than 5mΩ to prevent overheating caused by poor contact.

Third, fault handling and emergency measures

Common manifestations of seal failure

Charging interruption: Frequent error reports during the charging process (such as "insulation fault").

Abnormal heating: The temperature in the interface area is significantly higher than that in other parts.

Liquid leakage: There are water stains or rust inside the interface.

Emergency response methods

Immediate power-off: When any abnormality is detected, stop charging immediately and disconnect the power supply.

Temporary protection: Wrap the interface with dry insulating tape to prevent further water ingress or short circuit.

Professional maintenance: Contact the 4S store or authorized repair point. Do not disassemble the interface by yourself.

Long-term solution

Upgrade the sealing design: If the vehicle is frequently used in harsh environments, it is advisable to consider installing a waterproof cover or replacing the interface model with one that has better sealing performance.

Optimize charging habits: Avoid charging in extreme weather conditions (such as heavy rain and sandstorms), or choose charging devices with higher protection levels (such as IP68).

Fourth, user education and management

Operation training

Owner's Manual: It provides detailed instructions on the key points of maintaining the charging interface, including the replacement cycle of the sealing ring and the cleaning method, etc.

Charging station reminder: Post warning signs beside the charging piles to remind users to close the interface cover plate after charging.

Data monitoring

Intelligent diagnosis: Real-time monitoring of interface status through the on-board system or charging APP, and early warning of the risk of seal failure.

Historical record: Establish an interface maintenance file to record the time and content of each inspection and repair.

Summary

The maintenance of the sealing performance of the charging interface should be combined with daily prevention, regular inspection and timely repair. Users should develop good operating habits. Automakers and charging operators need to provide technical support and training to jointly ensure charging safety. If a seal failure is found, it is essential to follow the process of "power-off - protection - maintenance" to avoid causing more serious faults.