Energy Vehicle Charging Gun Housing

Xiamen Hongyu Intelligent Technology Co., Ltd. has been deeply engaged in the field of precise structural components for new energy charging and power supply for over a decade. It possesses an independent stamping production base, a research and development center, and a quality inspection laboratory. The "Energy Vehicle Charging Gun Housing" is one of the company's core output products, covering all categories of charging scenarios such as household AC, commercial DC, and portable emergency.

Precise protective housing, safeguarding the stable operation of the charging module

The product is made through precise stamping process, featuring high structural strength, resistance to impact and tolerance to outdoor environmental aging. The shell has stable tolerances and is suitable for assembling the internal components of the charging gun. It has excellent protective performance and can provide stable and reliable physical protection for the charging module. The performance test data of the product can be traced back, meeting the strict safety usage requirements of the new energy charging scenarios.

The metal protective cover of the charging gun ensures the long-term stability of the charging equipment.

1.A comprehensive energy vehicle component system covering all scenarios

As one of the core categories of Energy Auto Parts, the charging gun housing is a key protective component of the new energy charging system, directly determining the service life and operational stability of the charging equipment. The product uses high-quality cold-rolled steel or 6061 aluminum alloy as the base material, with a conventional material thickness ranging from 1.2mm to 2.5mm. According to the protection requirements, the material thickness and internal structure can be flexibly adjusted.

2.Convenient assembly and diverse surface treatments

The product is reserved with standardized component installation positions and wiring channels inside, compatible with mainstream charging gun control boards, contactors and heat dissipation modules. It can be quickly assembled without additional drilling. For different scenarios, various surface treatment solutions such as powder coating, anodizing and electrophoresis can be provided, balancing the anti-corrosion performance and appearance texture, meeting different positioning requirements from household charging stations to high-speed fast-charging stations.

3.Common application problems of charging gun housings

Regarding the Energy Vehicle Charging Gun Shell Question that is widely concerned in the industry, we have sorted out solutions to the frequently occurring problems based on our twenty-year production experience and customer feedback from over a thousand projects. The most concerned waterproof failure problem mostly results from unreasonable sealing slot design and excessive assembly tolerance. Our products adopt integrated stamping sealing slots, combined with customized foam rubber strips, controlling the assembly tolerance within ±0.05mm, reducing the risk of water seepage from the structural level.

Product attributes

Note: The above is our standard configuration. Specifications can be adjusted according to drawings and project requirements. Housing color, silk-screen logo and cutout positions are all customizable.

Integrated Adaptation of Charging Gun Shell for Charging Pile

The Energy Vehicle Charging Pile Charging Gun Shell is a core component of the station-level charging system, which needs to meet both the installation standards of the charging pile and the performance requirements of the charging gun. Our products continuously implement standardized quality control processes during production. Every batch of products undergoes multiple rounds of structural strength and protection performance tests before leaving the factory. The test data is fully archived and can be directly used for export projects and performance verification.

Adaptation and Integration Solution, Compatible with Multiple Specifications of Charging Equipment

For different types of charging piles, we can provide full customization services from interface size to appearance marking to ensure a seamless connection between the shell, the pole body, and the charging gun base. For different standards requirements in overseas markets, we can also quickly adjust the material and process plans to meet local safety and environmental protection regulations.Energy Vehicle Charging Gun Housing, as the front-end protective component of the entire charging system, its adaptability directly affects the operation and maintenance efficiency of the station. Our technical team can participate in the solution connection throughout the process to ensure the supporting effect.

Precision stamping process and quality control system

The Stamping Charging Pile Shell is produced using high-precision continuous stamping technology. Our own factory is equipped with 16 precision stamping machines ranging from 63 tons to 200 tons， along with an automated feeding and online inspection system. The daily production capacity can reach over 5，000 pieces， capable of handling large-scale orders. The entire production process follows strict quality control， with 6 inspection procedures from raw material entry to product outflow. The qualified rate of finished products is stable at over 99.5%， ensuring that each product meets the performance standards.

Custom Project Cooperation Process

1. Demand Connection：Collect technical requirements such as product specifications， operating conditions parameters，protection level， material， and surface treatment， and simultaneously assess the feasibility of the project.

2. Scheme Confirmation： Output the structural scheme and parameter list， clearly define tolerances， testing standards， and delivery cycle， and confirm the scheme with both parties.

3. Sample Production：Produce samples according to the final scheme， and simultaneously provide test materials， assembly guidelines.

4. Sample Verification： The customer conducts operating condition tests， provides test results， and makes necessary adjustments and optimizations as needed.

5. Sample Stabilization： After the sample tests are qualified， complete the sample sealing， and lock the production standards and technical documents.

6. Batch Production：Organize production according to the sample standards， and simultaneously implement the entire process of quality inspection.

7. Delivery and After-sales： Deliver goods as agreed， continuously provide technical support， and follow up on the implementation and usage of the products.

Why choose us?

We have been deeply involved in the field of new energy hardware components, fully understanding the stringent safety standards and long-term durability requirements for Energy Vehicle Charging Gun Housing. The entire process of test data is traceable, and precise control of assembly tolerances is implemented. From the structural design perspective, we can avoid common industry hazards such as water seepage and high-temperature deformation. Based on a large amount of on-site project experience, we can quickly respond to the needs of working condition verification, providing complete qualification documents and assembly drawings for your charging equipment, and offering stable and reliable protective housing solutions. If you need further assessment, please feel free to contact us by email.

FAQ

For charging guns of different power ratings, do the shells need to be designed differently in terms of heat dissipation and structural strength?

Yes. High-power DC guns generate more heat, so the shell structure should prioritize heat dissipation and reserve sufficient cooling space. At the same time, the wall thickness and strength need to be able to withstand the greater weight of the terminals. AC slow-charging guns have lower temperature rise, and they focus more on lightweight design, grip feel and appearance. We will adjust the wall thickness and internal support structure of the shell according to the rated current and temperature rise curve. In necessary cases, we will reserve cooling channels to balance strength, temperature rise and grip experience.

What types of 3D drawings or data can be used?

We support mainstream neutral 3D formats such as STEP, IGS, STP, and X_T, and can also receive native files from SolidWorks, UG, and Creo; at the same time, we are compatible with PDF engineering 2D drawings and dimension annotations. After receiving the files, we will verify key information such as size tolerances, chamfer angles, sealing structures, and snap-fit cooperation, and conduct DFM review. If you only have physical samples, we can also scan and reverse model them, confirm the structure, and then start mold production and prototyping.

What payment terms can you accept?

For new molds, a mold advance payment is required. For mass production orders, a partial production advance payment is generally charged, and the final payment is arranged to be settled before shipment. For long-term and stable cooperative customers, more flexible payment plans can be negotiated based on project size and cooperation cycle. All terms, amounts, and delivery dates will be clearly written on the PI-style invoice.

What surface treatments can you provide?

Common processing methods for charging gun shells: passivation, sandblasting, hard anodizing, electroplating, powder coating, oil spraying, laser engraving, and screen printing. Anodizing is wear-resistant and has good heat conductivity; powder coating is resistant to UV and resistant to outdoor salt spray, suitable for outdoor charging gun scenarios; passivation is suitable for basic rust prevention. We can match solutions based on your requirements for IP protection, scratch resistance, weather resistance, and appearance color, and also provide corresponding salt spray and wear resistance tests.

Can you perform heat treatment on the molds?

OK. The steel for the charging gun shell mold will undergo heat treatment. Commonly used molds include P20, 718H, and S136. Depending on the product output and surface requirements, quenching and tempering processes will be selected to enhance the hardness and wear resistance of the mold, reducing wear and sticking during mass production and extending the mold's lifespan. After the heat treatment, the mold will be further finely processed to ensure the accuracy of the cavity dimensions and avoid shell latch and sealing stopper size deviations.

How can I get a quotation?

Please send 3D model + 2D engineering drawings, material requirements, surface treatment, estimated annual demand, whether it is a new mold, target IP level, special testing standards, etc. to our email. After our engineers complete the DFM assessment, they will simultaneously provide mold fees, unit product price, delivery time, and test plan quotations. If there are no drawings, providing a physical sample can also be used for assessment and quotation.

How do you control quality?

Full-chain quality control: material verification of raw materials entering the factory → full-size inspection of the mold first piece FAI → confirmation of the first piece for mass production → process inspection and sampling → full inspection of the finished product. Key control focuses on the sealing stopper of the charging gun shell, latch size, hole position tolerance, and flatness; supporting rain, salt spray, and high/low temperature tests, providing size inspection reports, material certificates, and test records to ensure consistent shell assembly and IP protection stability.

Do you accept product customization?

We support full customization development of products, including shape structure adjustment, sealing structure optimization, opening hole layout, wall thickness adjustment, latch structure, color, surface processing. From DFM design review, mold development, sample verification to batch production, we cooperate with your charging station overall requirements iteration to meet the requirements for different power charging gun shell compatibility.

Can we place our logo on the product?

OK. We offer various printing methods such as screen printing, laser engraving, laser marking, and embedded nameplates to add the customer's logo. We will assess whether the logo position affects the sealing strength and assembly structure of the shell. For outdoor use, laser engraving is preferred as it is less prone to wear and detachment. You only need to provide a high-definition vector logo file. We will produce samples at the sample stage to confirm the effect.

What reliability risks should be considered in the structural design of the charging gun shell?

The charging gun shell is subject to repeated insertion and removal, handheld vibration, outdoor temperature fluctuations, etc. We focus on controlling several major risks: the sealing structure of the shell prevents water seepage and condensation; the wall thickness and reinforcement design avoid high-temperature creep and low-temperature cracking; the snap fasteners and assembly positioning structure prevent loosening after multiple insertions; the internal clearance structure ensures the space for cable bending, avoiding long-term compression and cracking of the cable. We will simultaneously assess the insertion fatigue and thermal expansion and contraction margin during the DFM stage, optimize the structure in advance, and reduce failure in the later mass production stage.