Analysis of Safety Lifespan and Charging Reliability of High-Power DC Charging Guns Based on Big Data

With the rapid development of the electric vehicle industry, the safety and reliability of high-power DC charging guns, as crucial facilities for EV charging, have increasingly gained attention. This study aims to systematically analyze and evaluate the electrical safety performance and service life of charging guns by developing an integrated performance testing device and corresponding big data analysis software. Firstly, a new type of charging gun testing device was developed. This device can accurately measure the withstand voltage, insulation resistance, resistivity, temperature, electromagnetic lock performance, and S2 mechanical switch performance of the charging gun. It also features remote data communication capabilities, enabling real-time data upload to a cloud platform. Subsequently, based on this real-time data, a set of big data analysis software was developed. This software can aggregate and analyze the collected data to generate detailed performance evaluation reports. Both charging and fault response are significantly affected by communication delays. With no delay, charging is instantaneous (0.5 s) and fault response is rapid (0.7 s). The study’s findings not only reveal the performance of charging guns under various conditions but also propose specific technical improvement recommendations based on data analysis results to enhance the performance and safety of charging guns. These outcomes hold significant theoretical and practical value for optimizing charging gun design and improving the safety of electric vehicle charging.