Durability, safety in EV charging cable assemblies

by Vianie Li & Cecile de Veyra

The rapid development of electric vehicles is driving the growth of the corresponding charging cable assembly market, opening up opportunities while also intensifying competition.

To vie for attention, Chinese companies are enhancing product stability and reliability. They use high-strength cables that will not be damaged when run over and equally sturdy connectors with a rubber safety cap. This cover not only prevents accidental touch but also protects the contacts from water and moisture that can cause corrosion.

Available in AC and DC types, mainstream EV charging cable assemblies in China use plugs compatible with CHAdeMO, Combo, Tesla, Mennekes and CEE chargers. These connectors have silver-plated copper alloy contacts and a UL94V-0-rated thermoplastic shell, and the copper cables have a TPE, PVC/HNBR or CPE/CR jacket. Mating cycles exceed 10,000 times at 45 to 80N force.

The selection, in terms of rated current and voltage, consists of 16, 32, 63 and 70A, and 120, 240 and 415VAC variants, with 16 and 32A units dominating shipments.

Most suppliers ensure products carry CE, UL and RoHS safety approvals. A few also secure a VDE certification.

All metal and plastic materials, including copper, silver, PVC and PE, are sourced domestically, although manufacturers can turn to foreign providers when required.

Input costs rose slightly in the past 12 months, which resulted in price adjustments, but are expected to stabilize in 2022.

Type 2 & Schuko plugs, with control box

With a control box, this Type 2-to-Schuko EV charging cable assembly from Hangzhou Onteck Industries Ltd, the EV-08, has 16A rated current. It complies with IEC 62196.

The minimum order quantity is 100 units. Lead time is 10 days.

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Type 2 & CEE plugs, with control box

From Hangzhou Onteck Industries Ltd, this EV-09 EV charging cable uses Type 2 and CEE plugs, and includes control box. The unit, with 32A rated current, meets IEC 62196 requirements.

The minimum order quantity required is 100 units. Delivery takes 10 days.

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Rated at 16, 20 or 32A

Huizhou Olink Technology Co. Ltd offers this LVDS Cable Assembly-OL-CVV-2795 for electric vehicle charging. This IP55 unit, with three charging modes, has 250 or 480VAC rated voltage and maximum 16, 20 or 32A rated current. It is UL94V-0-rated and conforms to IEC 62196-2.

The supplier requires a 1,000-unit minimum order. Lead time is seven days.

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250 or 480VAC rated voltage

For EV charging, this LVDS Cable Assembly-OL-CVV-2617 from Huizhou Olink Technology Co. Ltd has 250 or 480VAC rated voltage and maximum 16, 20 or 32A rated current. It has three charging modes. This UL94V-0-rated cable meets IEC 62196-2 requirements and has an IP55 rating.

An order of at least 1,000 units is delivered within seven days.

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Type 2, rated at 240V, 32A

Rated at 240V, 32A, this 5m-long Type 2 EV charging cable assembly from Zhejiang Vekon Technology Co. Ltd, the VCC-M2F2-132 EV, meets IEC 62196-2 guidelines.

The 10-unit minimum order has a 15-day lead time.

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Type 2, 5m

A Type 2 EV charging cable, the model VCC-M2F2-332 from Zhejiang Vekon Technology Co. Ltd has 415V and 32A rated voltage and current. This 5m-long unit meets IEC 62196-2 standard.

The minimum order quantity is 10 units. Delivery takes 15 days.

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