Methods for maintaining the charging module of electric vehicle chargers

The methods for maintaining the charging module of an electric vehicle charger can be approached from three aspects: daily use, troubleshooting, and regular maintenance, as follows:

First, daily use and maintenance

Dedicated charger and correct operation

The charger parameters vary among different vehicle models. It is necessary to use the original or a dedicated charger that is compatible to avoid random replacement.

When charging, align the charging port accurately to avoid suspending the cable in the air and prevent excessive pressure or loosening at the interface.

During the charging process, it is necessary to ensure good ventilation of the charger to prevent the plug from overheating, which may lead to short circuits or poor contact.

Charging habits and battery protection

The battery should be charged in time within 12 hours after discharging to prevent the formation of sulfidation crystals, which could lead to a decrease in capacity.

To prevent the battery from being in a state of low charge for a long time and reduce high-current discharge (such as stepping hard on the accelerator to accelerate), the aging of the battery can be slowed down.

Regularly perform deep discharges to activate battery properties and increase battery capacity.

Storage and movement protection

The charger is not designed for vehicles and is not resistant to strong vibrations. When moving it, it should be wrapped in foam plastic to prevent damage from jolting.

When storing, it is necessary to maintain the battery power and avoid long-term low-power storage to prevent performance decline.

Second, troubleshooting and maintenance

Fault diagnosis steps

Visual inspection: Observe the charger display screen or indicator lights to determine if there are any fault prompts or abnormal states.

Power supply testing: Use a multimeter to check if the input voltage and current are stable, and inspect whether the power plug and socket have good contact.

Interface inspection: Check if the charging interface is loose, damaged or contaminated, and ensure that the interface is clean and free of impurities.

Connection test: If the charging module fails to recognize the vehicle, it is necessary to check whether the charging plug is firmly connected and whether the connection part between the plug and the vehicle is clean.

Key points of maintenance implementation

Locate the fault: Based on the fault diagnosis results, determine the location of the fault, such as whether components like capacitors and resistors are damaged, or whether key parts like communication circuits and battery voltage monitoring circuits are functioning properly.

Replace components: If component damage is diagnosed, select the appropriate component specification for replacement and ensure that the soldering is firm.

Third, regular maintenance and inspection

Cleaning and heat dissipation inspection

Regularly clean the dust and impurities inside the charging interface and charging module to keep the equipment clean and dry.

Check whether the heat dissipation system is operating normally to ensure that the charging module does not overheat.

Functional testing and debugging

After replacing or adjusting the components, conduct functional tests on the charging module, including tests for functions such as startup, vehicle recognition, and charging speed, and record the test results.

Based on the test results, debug and optimize the charging module to ensure the normal operation of the equipment and meet the usage requirements.

Acceptance and delivery inspection

The acceptance content includes the appearance inspection of the charging module, mainly checking whether there is any damage, deformation or other conditions.

Conduct functional tests and safety tests, mainly to check whether the charging function is normal and whether the safety performance such as insulation resistance and grounding resistance complies with national standards.