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解决方案

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Charging Gun and
Charging Station Industry

方案背景

行业痛点

Continuous power upgrade of charging devices raises strict harness requirements, traditional soldering overheats easily under frequent plugging and shortens device service life.

Power Upgrade

Rated power & current of AC/DC charging equipment keep increasing

Strict Spec

Harness needs high-current, waterproof and anti-EMI performance

Process Defect

Soldered terminals overheat and ablate under frequent plugging

Safety Risk

Obsolete technology reduces equipment safety and service life

With the continuous upgrade of new energy charging power, charging wiring harnesses face stringent requirements of high current, high waterproof performance and anti-electromagnetic interference. Traditional soldering processes are prone to overheating and ablation under frequent plugging and unplugging conditions, restricting the safety and service life of charging equipment.

解决方案

Core Idea

Leveraging core ultrasonic welding technology, Himinsen customizes full-life-cycle high-current wiring harness solutions for charging equipment manufacturers, covering R&D design, precision welding, processing forming and finished product testing. Compliant with national GB/T standards and IEC charging equipment specifications, we provide one-stop supporting services for AC and DC charging gun and charging pile manufacturers.

Process Innovation

Ultrasonic welding replaces traditional soldering for working conditions of frequent plugging and continuous high-current operation of charging guns, achieving low-impedance and high-current connection, effectively reducing operating temperature and eliminating long-term ablation risks.

Automation Integration

Integrating wire cutting, stripping, crimping, welding and pressure resistance testing into an integrated automatic production line to improve batch production efficiency.

Digital Management

Connecting with MES to realize accessible production data and full-process quality monitoring, meeting the traceability requirements of charging equipment.

Customized Adaptation

Design exclusive processing solutions for thin wires of handheld charging guns and thick cables of cabinet-type charging piles by specifications.

Implementation path

Based on the core of "automation + ultrasonic technology + digitalization", a complete closed-loop solution covering the entire process from design, processing to inspection is constructed: