Issues with Electric Vehicle Charging Cable Connection Equipment

Internal core wire breakage or poor contact within the cable can cause intermittent charging. Frequent bending, excessive pulling of the cable, or oxidation and corrosion of metal conductors after prolonged use may all contribute to this issue. Additionally, loose connections between the cable plug and the charging station or vehicle interface can result in unstable contact. Try replacing the plug or the entire cable, and ensure proper usage habits. )

Description: Frequent charging interruptions in electric vehicle charging guns require a multi-dimensional analysis of causes, including hardware contact, communication protocols, and safety protections. The following is an analysis of core issues:

1. Abnormal contact at the charging interface

Foreign objects or oxidation interference: Dust or moisture accumulation inside the charging gun plug (e.g., GB/T 20234 interface) or vehicle charging port can cause poor contact in the CC (Charging Connection Confirmation)/CP (Control Guidance) signal lines; oxidation of copper terminals increases contact resistance, triggering communication timeout interruptions.

Mechanical structural faults: Locking mechanisms jam (e.g., electronic locks not fully engaged), interface spring plates deformed, or charging gun plug wear, causing unstable physical connections and sudden high-voltage circuit disconnections.

2. Communication protocol handshake failure

Protocol compatibility issues: The charging station and vehicle support incompatible charging protocols (e.g., CCS, GB/T, CHAdeMO standard conflicts), resulting in failed agreement on parameters (e.g., maximum current, voltage) during the handshake phase, leading to charging initialization failure.

Signal transmission failure: Poor contact or electromagnetic interference (e.g., nearby strong magnetic field devices) on the CAN bus signal lines (e.g., CAN_H/CAN_L in fast-charging cables) causes interruption in charging status data transmission, prompting the BMS (Battery Management System) to actively cut off power.

3. Overheating or overcurrent protection triggered

Cable or interface overheating: Prolonged fast charging causes internal resistance heating in the cable (＞60℃), triggering overheating protection via the charging station's built-in temperature sensor; poor interface contact generates arcs, causing localized temperature spikes detected by the BMS.

Abnormal current fluctuations: Battery module faults (such as voltage imbalance in individual cells) cause sudden changes in charging current, exceeding the charging station's current limit threshold, prompting the system to automatically execute disconnection protection.

4. Battery Management System (BMS) Abnormalities

Battery state lock: When the battery temperature is below 0°C or above 50°C, the BMS activates thermal management priority mode and pauses charging; if the remaining state of charge (SOC) display is abnormal or the battery health (SOH) is below the threshold, the system prohibits charging to avoid risks.

Software Logic Errors: If the vehicle's system firmware version is too low, there may be vulnerabilities in the charging control logic, potentially causing the system to mistakenly identify the battery as "fully charged" or in a "fault state" and prematurely interrupt charging.

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