New Energy Power truck parts High voltage DC charging dock with cable assembly 2105011-KT8A0

Built to meet the high-efficiency charging demands of commercial NEVs, this assembly delivers exceptional power transmission capabilities. The integrated cable features a 95mm² cross-section conductor made of 99.9% pure oxygen-free copper (OFC), with a 7×37 strand structure that minimizes DC resistance to ≤0.00019Ω/m. This low resistance enables a maximum charging power of 280kW, allowing a 200kWh battery pack to charge from 20% to 80% in just 35 minutes—cutting charging time by 30% compared to standard 200A assemblies. The charging dock’s internal current collector uses silver-plated copper contacts to reduce contact resistance, ensuring stable current delivery even at peak loads, while the 3m cable length provides flexible maneuverability for docking with various charging pile layouts

Engineered as a safety-critical component for high-voltage charging, the assembly integrates comprehensive protective mechanisms. The charging dock features IP67 waterproof/dustproof rating (tested to 1m water immersion for 30 minutes) and a built-in DC insulation monitoring module that triggers shutdown if insulation resistance drops below 500Ω/V. The cable’s insulation uses cross-linked polyethylene (XLPE) with 18kV/mm dielectric strength, resisting 160℃ continuous temperature to prevent breakdown. A double-layer shielding (copper braid + aluminum foil, coverage ≥98%) isolates electromagnetic interference (EMI) from charging piles, protecting the vehicle’s BMS. Additional safeguards include over-voltage (≥880V), over-current (≥400A), and short-circuit protection, complying with IEC 61851-23 safety standards

Designed for the rigorous usage of commercial NEVs (up to 10 charging cycles per day), the assembly exhibits exceptional wear and environmental resistance. The charging dock’s housing is made of flame-retardant ABS+PC alloy (UL94 V-0 rating) with a scratch-resistant coating, resisting impact from road debris and daily handling. The cable’s outer sheath uses oil-resistant EPDM rubber that maintains flexibility at -40℃ (northeast China winters) and resists aging at 95℃ (engine bay heat), passing 3000-hour thermal cycle testing (-30℃ to 110℃). The dock’s contacts withstand 10,000 insertion/removal cycles without performance degradation, while the entire assembly passes 500,000 vibration cycles (ISO 16750-3) and 1200-hour salt spray testing (ASTM B117), ensuring an 8-year/400,000km service life

Optimized for fleet maintenance and driver convenience, the assembly features a user-centric design. The charging dock’s flange-mounted structure uses 4 M12×30 high-strength bolts that match the vehicle’s original mounting holes, allowing two technicians to complete installation in 45 minutes with only a torque wrench (35-40N·m). The dock’s LED status indicators (red for standby, green for charging, yellow for fault) provide clear visual feedback to drivers, while the integrated cable’s anti-tangle design reduces kinking during use. A quick-release latch on the dock’s cover simplifies cleaning, and the cable’s connector includes a locking mechanism to prevent accidental disconnection during charging. The pre-assembled design eliminates on-site wiring, reducing labor costs and ensuring consistent installation quality across fleets