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Standards Development
This document applies to the couplers of portable battery chargers for electric vehicle conductive charging connection systems, with a rated operating voltage not exceeding 48 V DC and a rated current not exceeding 16 A.
The connector of the coupler is integral with the battery charger that comply with the requirements of IEC TS 61851-3 and/or IEC 60335-2-29, and the inlet of the coupler is integrated to the corresponding batteries, connecting the chargers and batteries for power and signal transmission.
This document specifies the technical requirements and test methods of the couplers for portable battery chargers, including marking, construction, protection against electric shock, temperature rise, mechanical strength, thermal cycling, humidity exposure, resistance to vibration，resistance to corrosion and so on. Meanwhile, the configurations of this coupler are recommended in this document.
This document applies to the accessories for primary use outdoors when the ambient temperature is normally within the range of -25 °C to +55 °C.
Electric bicycles are lightweight, convenient, economical, and environmentally friendly. It is necessary to use portable battery chargers, such as Asia, with voltage conversion function (compliant with IEC TS 61851-3 and/or IEC 60335-2-29, achieving AC/DC conversion and voltage reduction) to charge vehicle batteries.
These charging couplers have a minor operating voltage and current. The operating voltage of the charging couplers is generally below 48V DC and the operating current is generally below 16A DC. They are usually used outdoors and withstand long-term exposure to sunlight and rain, frequent insertion and withdrawal, frequent temperature changes, vibration during bicycles operation and so on. The product needs to have enough mechanical, electrical, and environmental adaptability to ensure safety and reliability.
IEC 60335-2-29 applies to a battery charger entirety, and without specific technical requirements for the charging couplers. IEC 62196-4 and IEC 62196-6 specify DC pin and contact-tube accessories, which are applicable to circuits with DC electric vehicle supply equipment specified in IEC 61851-3 and IEC 61851-25. However, the couplers specified in this document are mainly applied to portable battery chargers that take power from the AC power supply. IEC 60320 only applies to the appliance couplers with the rated voltage no exceed 250 V (AC) and the rated current no exceed 16 A. IEC 61984 applies to connectors with rated voltages above 50 V and up to1000 V AC and DC and rated currents up to 125 A per contact. The voltage range covered by IEC 61984 is too high for electric bicycle charging couplers, and there are no technical requirements, such as temperature cycling, alternating humidity and heat, vibration resistance, etc. for complex and variable usage environments, and the technical requirements are lower, which are suitable for general connectors without detailed specifications.
This document aims at developing a product standard for the couplers of portable battery chargers for electric vehicle conductive charging connection systems, so as to solve the problems mentioned above and making international technical requirements reach an agreement.
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