Zhongyao Information_Zhongyao Information_Dongguan Zhongyao automation equipment Co., Ltd

03-11 

"Charging Guns in Every Home: Do You Know the Industry Specs?"

As a core component of the EV charging station, the charging gun directly reflects the overall quality of the station. If the specifications, material quality, and manufacturing processes of the charging gun cable assembly fail to meet the required standards, it will pose unpredictable safety hazards and cause irreversible damage to your vehicle's battery. Since Zhongyao Automation frequently customizes automated production lines for charging gun cable assemblies and connectors for major new energy vehicle manufacturers, we would like to share some professional insights into the manufacturing processes and key considerations regarding charging guns. As a critical safety component in the new energy vehicle charging system, the specifications and manufacturing processes of charging gun cable assemblies are strictly regulated by national and international standards. Core Specification Standards The specifications for charging gun cable assemblies primarily adhere to the following national standards. Cable Body Standard: GB/T 33594-2017 This is currently the most core domestic standard dedicated to cables for electric vehicles. Voltage Rating: Applicable to cables with a rated AC voltage not exceeding 0.6/1kV and a rated DC voltage not exceeding 1.5kV. The latest connection device standards have upgraded the DC voltage specification to 1500V. Conductor Specifications: Conductors must use oxygen-free copper with a purity of ≥99.9%. Common cross-sectional area specifications include 0.5, 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50, and 70 mm². Low Power (e.g., 7kW): Typically uses 3×6mm² or 3×10mm² cables. High Power (e.g., 60kW and above): Typically uses cables with cross-sectional areas of 35mm², 50mm², or even larger, often incorporating liquid cooling technology for heat dissipation. Material Characteristics: Insulation and sheath materials must possess excellent oil resistance, ozone resistance, weather resistance (UV protection), and flame retardancy (typically required to meet VW-1 or FT1 levels). Flexibility Requirements: Since charging gun cables require frequent bending and dragging, the standard mandates that they must pass rigorous flexing life tests (typically requiring tens of thousands of bending cycles without breakage). Connection System and Interface Standard: GB/T 20234 Series This series of standards specifies the physical dimensions, electrical parameters, and general requirements for charging interfaces, ensuring compatibility between charging equipment and vehicles. GB/T 20234.1: General requirements. GB/T 20234.2: AC charging interface. GB/T 20234.3: DC charging interface. Other Related Standards Energy Industry Standards: Such as NB/T 33001 and NB/T 33002, which specify connection specifications and temperature rise limits for charging stations and their internal cable assemblies. International Standards: Exports or specific markets may also need to comply with IEC 62893 (International), EN 50620 (Europe), UL 2263 (USA), and other standards. Manufacturing Process Standards The manufacturing process for charging gun cable assemblies is a meticulous procedure designed to ensure electrical performance, mechanical strength, and environmental adaptability. The main processes include. Design and Material Selection Based on charging power (AC slow charging/DC fast charging) and current magnitude, select appropriate cable specifications (cross-sectional area, voltage rating) and connector models. Conductors typically use oxygen-free copper or tin-plated copper, while sheath materials are selected from wear-resistant, high/low temperature resistant TPE/TPU, etc. Cable Pre-processing Cutting: Precisely cut cables to the length specified in the drawings, with tolerances typically controlled within ±1mm. Stripping: Use laser or mechanical methods to strip the outer jacket and insulation, exposing the conductor to the specified length, while avoiding damage to the copper strands during the process. Shielding Treatment: For cables with shielding layers, the braided shield must be grounded or fitted with metal sleeving to reduce electromagnetic interference. Terminal Crimping Use professional crimping equipment to tightly crimp terminals onto the wire cores. Crimping quality is critical and must be inspected through methods like cross-sectional analysis to ensure airtightness and uniformity, guaranteeing that crimping pull force meets standards (e.g., ≥50N). Injection Molding and Assembly Secondary Injection Molding: Inject sealing compound (such as silicone) at the connector interface to achieve high levels of water and dust resistance, such as IP67/IP68. Cable Assembly Fixing: Use cable ties, heat shrink tubing, or rubber sleeves to layer and secure the internal cable assembly, preventing internal friction and loosening. Testing and Certification Finished products must pass a series of rigorous tests before leaving the factory to ensure safety and reliability.

03-10 

Standards and Processes for EV Charging Pile Wire Harnesses and Connectors

With the proliferation of charging pile brands in the current market, product quality varies significantly. Consequently, the material selection standards and processing craftsmanship for charging pile wire harnesses and connectors serve as the cornerstone of overall system quality. Our company frequently receives inquiries regarding automation solutions for new energy vehicle (EV) charging infrastructure. Having successfully delivered automated production lines for charging harnesses and connectors, we aim to clarify the critical knowledge, processing workflows, and industry standards in this sector to address common client concerns. EV charging pile wire harnesses (including charging gun cables and internal high-voltage harnesses) are critical safety components in the EV charging ecosystem. Their specifications and processing requirements are extremely stringent, governed by Chinese National Standards (GB), Energy Industry Standards (NB/T), and International Standards (such as IEC and UL). The following is a detailed analysis of these specifications and process requirements. I. Core Specification Standards 1. Cable Body Standards GB/T 33594-2017 "Cables for Electric Vehicle Charging": This is the core domestic specialized standard. Applicability: Rated AC voltage ≤ 0.6/1kV; Rated DC voltage ≤ 1.5kV. Conductor Specifications: Common cross-sectional areas include 0.5, 1, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50, and 70 mm². Low Power (7kW): Typically utilizes 3×6mm² or 3×10mm² configurations. High Power (60kW - 120kW+): Typically utilizes 35mm², 50mm², or larger, often incorporating liquid cooling technology. Structural Requirements: Conductor + Separator + Insulation + Inner Sheath + Shielding Layer (if applicable) + Outer Sheath. Material Characteristics: Must use Oxygen-Free Copper (purity ≥ 99.9%). Insulation and sheathing materials must possess excellent oil resistance, ozone resistance, weather resistance (UV stability), and flame retardancy (typically requiring VW-1 or FT1 ratings). Flexibility Requirements: Charging gun cables undergo frequent bending and dragging. Standards mandate rigorous bending life testing (typically requiring tens of thousands of cycles without fracture). 2. Connection System and Interface Standards GB/T 20234 Series: Defines physical interface dimensions and electrical parameters. GB/T 20234.1 (General Requirements) GB/T 20234.2 (AC Charging Interface) GB/T 20234.3 (DC Charging Interface) NB/T 33002-2018 "Technical Conditions for EV AC Charging Piles" & NB/T 33001: Specify connection norms and temperature rise limits for the charging pile assembly and internal harnesses. 3. Safety and Performance Standards GB/T 18487 Series: General requirements for conductive charging systems and Electromagnetic Compatibility (EMC). UL 2251 / IEC 62196: For export products, compliance with US UL or international IEC standards is required, imposing additional requirements on fire resistance ratings and mechanical strength. II. Key Processing Craftsmanship Requirements The manufacturing of charging pile harnesses must be conducted in a highly controlled environment. The primary processes and standards are as follows: 1. Cutting and Stripping Precision Control: Length tolerance is typically controlled within ±1mm. Zero-Damage Tolerance: It is strictly prohibited to damage conductor strands during stripping. For multi-strand, fine-twisted high-flexibility cables, laser stripping or precision mechanical stripping must be employed to ensure a 0% strand breakage rate. Broken strands can lead to reduced current-carrying capacity and localized overheating. 2. Terminal Crimping Crimping Standards: Must comply with QC/T 29106 or USCAR-21 standards. Key Indicators: Pull-out Force: Must meet the minimum tensile force specified by standards (ranging from hundreds to thousands of Newtons depending on wire gauge). Crimp Height/Width: Must remain within tolerance to minimize electrical contact resistance. Micro-Metallographic Analysis: Regular cross-sectioning is required to verify a proper metal interdiffusion layer between the conductor and terminal, ensuring no oxidation or voids. Terminal Types: High-current terminals often utilize copper-aluminum transitions or silver/tin plating to reduce contact resistance and prevent oxidation. 3. Shielding Treatment Objective: To prevent high-frequency interference during the charging process (EMC). Process: For braided shielding meshes, coverage density is typically required to be ≥85%. Shield grounding must utilize dedicated shield clips or a 360-degree ring termination process to ensure effective grounding for both low and high frequencies. Foil shielding must be secured with conductive tape, with an overlap width of ≥5mm. 4. Overmolding and Assembly Connector Overmolding: The junction between the charging gun head and the cable typically employs a

03-07 

Who establishes the specification standards for automotive battery pack harnesses, and what manufacturing processes are required?

Specifications and Manufacturing Processes for Automotive Battery Pack Harnesses (High-Voltage) The specifications for automotive battery pack harnesses, particularly high-voltage (HV) harnesses, are established through a multi-tiered framework involving national standards committees, industry associations, international standardization bodies, and original equipment manufacturers (OEMs). The manufacturing processes require highly automated and precision-engineered workflows (referencing the HV harness processing flow and craftsmanship provided by Dongguan Zhongyao Automation in Section 2 below) to ensure safety and reliability under high-voltage and high-current conditions. I. Standard-Setting Bodies and Key Specifications The standardization system for automotive battery pack harnesses is a comprehensive hierarchy comprising National Standards (GB), Industry Standards (QC), Group/Association Standards (T), and Enterprise Standards (OEM). 1. National and Industry Standard-Setting Bodies National Technical Committee for Automobile Standardization (SAC/TC114): The core authority for standard attribution in China. Its sub-committee, the Electric Vehicle Division (TC114/SC27), is specifically responsible for EV-related standards, including HV harnesses. Core National Standard: GB/T 37133-2018 "Technical Requirements for High-Voltage and High-Current Cables and Connectors for Electric Vehicles." This is the critical mandatory reference standard defining electrical performance, mechanical properties, and environmental adaptability. Related National Standards: GB/T 18384 (Safety requirements for electric vehicles), GB/T 25085/25087 (Road vehicles – Cables). Ministry of Industry and Information Technology (MIIT): As the regulatory authority, it issues industry standards (e.g., the QC/T series). Industry Standard: QC/T 29106-2014 "Technical Conditions for Automotive Wire Harnesses." While older, it remains a foundational general standard; new group standards are currently being converted to address specific NEV requirements. 2. Group Standards and Associations China Association of Automobile Manufacturers (CAAM) and various electronics/electrical associations: These bodies issue group standards that adapt rapidly to emerging technologies, often outpacing national standards. Examples: T/ZS 0319-2022 "New Energy Electric Vehicle Wire Harnesses" and T/CASME 682-2023 "Technical Requirements for Power Wire Harnesses of New Energy Vehicles." These standards provide detailed regulations for new scenarios such as 800V high-voltage platforms and solid-state battery adaptation. 3. International Standards ISO (International Organization for Standardization): e.g., ISO 6722 (Road vehicles – 60 V and 600 V single-core cables), ISO 19642 (New series of road vehicle cable standards). SAE (Society of Automotive Engineers): e.g., SAE J1128 (Low-voltage cables), SAE J1742 (High-voltage connectors). These are frequently referenced by export-oriented OEMs and joint ventures. 4. OEM Enterprise Standards Most Binding Constraints: In actual production, major OEMs such as Volkswagen (VW 80303/PV series), General Motors (GMW), Ford (WSS), Tesla, and domestic leaders like BYD and Geely maintain their own proprietary technical specifications. Characteristics: These standards are typically more stringent than national standards, specifying precise metrics for lifecycle testing (e.g., vibration resistance, high-voltage impulse, salt spray duration) and shielding effectiveness values. II. Manufacturing Methods and Process Flow (Process solution provided by Dongguan Zhongyao Automation) The manufacturing of automotive battery pack harnesses, especially high-voltage orange cables, differs significantly from low-voltage harnesses. Due to extreme requirements for safety, shielding integrity, and consistency, the process utilizes a combination of semi-automated and fully automated systems. 1. Core Manufacturing Process Flow Cutting: Process: Utilizes CNC cutting machines to precisely slice HV cables according to engineering drawings. Requirements: Cuts must be flat without damaging internal conductors; length tolerance is typically controlled within ±1mm. Stripping: Key Challenge: HV cables often feature multi-layer structures (outer insulation, shielding braid, inner insulation). This requires coaxial stripping machines or multi-step stripping processes. Requirements: Must not damage the shielding braid or inner conductor; stripping length precision must be extremely high. Shielding Processing: Critical Step: Unique to HV harnesses. Involves folding back and combing the exposed metal braiding, followed by the installation of a Shielding Ring or grounding terminal. Objective: To ensure Electromagnetic Compatibility (EMC) and prevent high-voltage interference with vehicle electronics. Crimping: Process: Uses high-precision servo crimping

03-06 

Where lie the processing challenges for automotive Ethernet harnesses, and how can automation be achieved?

Processing Challenges and Automation Roadmap for Automotive Ethernet Harnesses Technical Analysis by Dongguan Zhongyao Automation Compared to traditional low-voltage harnesses, the manufacturing of Automotive Ethernet Harnesses presents significantly higher technical barriers. As automotive electronic architectures evolve toward domain control and central computing, the surging demand for bandwidth and electromagnetic immunity has made Ethernet harness processing—particularly for twisted pair cables—a critical industry bottleneck. The following is a detailed analysis by Dongguan Zhongyao Automation regarding these processing challenges and our strategic roadmap for automation implementation. I. Key Processing Challenges for Automotive Ethernet Harnesses Ethernet harnesses typically utilize Unshielded Twisted Pair (UTP) or Shielded Twisted Pair (STP) cables. Their unique physical properties dictate specific high-difficulty processing requirements: 1. Maintenance of Twist Structure and Untwisting Control Challenge: Ethernet signal integrity relies on the twist pitch to cancel electromagnetic interference (EMI). During stripping and termination, excessive untwisting or structural damage leads to impedance mismatch and crosstalk, directly degrading communication quality (critical for 100BASE-T1 and 1000BASE-T1 standards). Difficulty: Traditional methods struggle to precisely control untwisted lengths (typically required to be <13mm or less), resulting in poor consistency with manual operations. 2. High-Precision Stripping and Insulation Integrity Challenge: Ethernet cables are often fine-gauge (e.g., AWG 22-26) with thin insulation. Conventional blade stripping risks nicking conductors or altering their cross-sectional area, causing increased resistance and signal reflection. Difficulty: Requires micron-level stripping precision without damaging underlying shield layers (if present). 3. Complex Shield Handling (for STP Cables) Challenge: STP cables contain aluminum foil and braided shields. Manual handling of the braid (folding, combing, and crimping) is prone to burrs, strand breakage, or poor contact, leading to grounding failures and EMI issues. Difficulty: Automated combing and forming of the braided shield remain a significant bottleneck in automation. 4. Specialized Terminal Crimping and Impedance Matching Challenge: Ethernet connectors (e.g., HSD, MATE-AX, Mini-FAKRA) often employ multi-core simultaneous crimping or specialized Insulation Displacement Connection (IDC) technologies. Crimping force and positioning directly impact characteristic impedance (typically 100Ω). Difficulty: Conventional crimping machines cannot meet the strict geometric tolerances required for high-frequency signal transmission. 5. Stringent Testing Standards Challenge: Beyond standard continuity checks, mandatory Time Domain Reflectometry (TDR) testing is required to verify impedance continuity, alongside high-frequency parameter tests such as Return Loss and Insertion Loss. Difficulty: Real-time 100% inline inspection entails high costs and requires sophisticated equipment. II. Automation Implementation Roadmap Addressing these challenges, Dongguan Zhongyao Automation is transitioning from "single-machine automation" to "intelligent full-line solutions." Aligned with 2025-2026 technology trends, our primary implementation paths are: 1. Upgrading Core Process Equipment (Hardware Level) Intelligent Stripping Technologies: Laser Stripping: Utilizes laser ablation to precisely remove insulation without conductor damage, ideal for fine coaxial and twisted pair cables, eliminating blade-induced defects. Thermal/Ultrasonic Stripping: Enables stress-free cutting for specialized insulation materials. Visual Feedback Loop: Integrates CCD cameras to monitor stripping length and untwisting status in real-time, automatically adjusting tool parameters. Automatic Untwisting and Wire Management Units: Deployment of dedicated servo-controlled untwisting mechanisms that reverse-rotate based on preset pitches. This controls untwisted length within millimeter-level tolerance and can automatically restore partial twists or maintain specific geometries prior to crimping. Automated Shield Handling: Introduction of automatic folding and brushing mechanisms. Robotic arms equipped with pneumatic tools uniformly comb the braided shield, fold it over the insulation, and secure it via automatic heat-shrink tubing or adhesive dispensing, replacing manual labor. High-Precision Crimping and Assembly: Utilization of multi-station fully automatic crimping machines capable of simultaneous multi-wire feeding and crimping. Integration of Crimp Force Monitoring (CFM) systems to track every terminal's crimp curve in real-time, ensuring electrical compliance. For connectors like HSD, automatic pin insertion machines with visual positioning ensure precise pin alignment.

04-13 

The use of automation technology in non-standard equipment

The application of automated non-standard equipment can meet the special requirements of products from time to time, and can also improve production efficiency, which is also very helpful to the management of enterprises and is conducive to the temporary development of enterprises.

04-13 

The innovation of automation technology provides the necessary conditions

The development of modern production and science and technology. At the same time, it also provides the necessary conditions for the innovation of automation technology. After the 1970s, automation began to develop towards complex system control and advanced intelligent control, and was widely used in various fields such as national defense, scientific research, and economics to achieve larger-scale automation, such as integrated automation systems for large enterprises, national railways. Automatic dispatching system, automatic dispatching system of national power grid, air traffic control system, urban traffic control system, automatic command system, national economic management system, etc. The application of automation is expanding from the engineering field to the non-engineering field, such as medical automation, population control, economic management automation and so on. Automation will imitate human intelligence to a greater extent. Robots have been applied in industrial production, ocean development, and space exploration. Expert systems have achieved remarkable results in medical diagnosis and geological exploration. Factory automation, office automation, home automation and agricultural automation will become an important part of the new technology revolution and develop rapidly.

04-13 

At present, the fierce market competition of non-standard automation equipment

It is the attention to the integration of culture and individual taste in industrial design. Now non-standard automation equipment. However, it is rare to bring various cultural connotations into it as design concepts from the very beginning of the design. Zhongyao Automation R&D team has been working on exploration and attempts in this area since a year ago. Extensive and in-depth research on non-standard automation equipment available on the market.

04-13 

Application characteristics of non-standard automation equipment

The touch screen is used as the man-machine interface, and the PLC programmable logic controller is used to control the entire automatic production process. The air cylinder and the motor cooperate to perform automatic actions, with stable performance and simple operation. The feeding of the accessories is manual feeding and automatic feeding. It is simple and fast. Second, the workpiece loading and unloading (up and down line) adopts manual mode. Easy maintenance and low failure rate.