Abstract: A power connector includes a housing having terminal channels holding charging terminals for mating with a charging connector. Power conductors are terminated to cable connectors of the corresponding charging terminals. The power connector includes a cooling module thermally coupled to the charging terminals. The cooling module includes a carrier having pockets. The cooling module includes phase change elements received in the corresponding pockets and held relative to each other by the carrier. The phase change elements are thermally coupled to the corresponding cable connectors to lower operating temperatures of the charging terminals during charging.

Abstract: A charging health monitoring device for monitoring a health of a charging component for an electric vehicle includes a testing sensor held by a charging terminal and including a testing probe interfacing with a mating charging terminal. The charging health monitoring device includes a control circuit for controlling a charging operation and a testing operation. The control circuit measures a terminal voltage of the charging terminal and a sensor voltage of the testing sensor to determine resistance of the charging terminal and provide a test signal. The control circuit includes an electrically isolated switch receiving the test signal and generating a control signal based on the test signal for controlling a charging operation of the charging component. The control circuit performs the testing operation simultaneously with the charging operation.

Abstract: A charging inlet assembly for an electric vehicle includes a charging inlet housing, charging terminals held in the charging inlet housing, and a temperature sensor plugged into the charging inlet housing for monitoring temperature of at least one of the charging terminals.

Abstract: A charging station health monitoring device for monitoring a health of a charging socket of a charging station includes a device housing having a user interface. The charging station health monitoring device includes a control panel in the device housing. The control panel operably coupled to the user interface. The charging station health monitoring device includes a testing sensor coupled to the control panel. The testing sensor coupled to the control panel. The testing sensor includes a testing pin, a testing probe, and an insulator between the testing pin and the testing probe. The testing pin includes a pin interface. The testing probe includes a probe interface. The probe interface spaced apart from the pin interface. The testing sensor is configured to be plugged into the charging socket such that the pin interface and the probe interface are configured to engage the charging socket at different testing locations to determine a resistance measurement for the charging socket.

Abstract: A power harness for a charging inlet assembly includes a harness housing holding a power cable in a cable slot A ring insert of the power cable is aligned with a bore of a hub of the housing that receives a threaded bolt with an insulating cover and an insulating cap. A contact ring is received in the hub with a first end connected to the ring insert and a second end electrically connected to a charging terminal. A threaded socket is received in the hub and passes through the contact ring for threadably coupling to the charging terminal. The outer end of the threaded socket has a threaded bore receiving the threaded shaft of the threaded bolt.

Abstract: A charging inlet for an electric vehicle includes a housing, a terminal arranged within the housing for engaging with a corresponding mating terminal of a charging plug, and a sensor connectable to a monitoring system of the electric vehicle for detecting the presence of a charging plug installed within the charging inlet.

Abstract: A wire harness for a charging inlet of a vehicle includes first and second high voltage wires having first and second conductors. An inline disconnect electrically connects the first and second conductors and is configured to allow the conductors to be disconnected. The inline disconnect includes a housing having a central cavity, a first chamber at a first end that receives the first high voltage wire, and a second chamber open to the central cavity at a second end that receives the second high voltage wire. First and second disconnect contacts terminated to the conductors are received in the central cavity. A connecting element couples the first and second disconnect contacts and is removable from the disconnect contacts to allow disconnection of the first and second disconnect contacts to electrically separate the first and second high voltage wires.

Abstract: A wire guide assembly includes a seal cover having a cover opening defined therethrough and a fixation element. A seal is fitted to the seal cover and defines a seal opening aligned with the cover opening in an axial direction of the assembly. A strain relief guide of the assembly is fitted to a side of the seal opposite the seal cover and defines a guide opening aligned with the seal opening and the cover opening in the axial direction.

Abstract: A power connector includes a housing having a terminal channel and a terminal received in the terminal channel including a mating pin at a front of the terminal and a cable connector at a rear of the terminal. The mating pin is positioned in the terminal channel for mating with a charging connector. The cable connector includes a pad configured to be terminated to a power cable. The power connector includes a heat exchanger thermally coupled to the pad of the terminal. The heat exchanger includes a coolant channel for coolant flow through the heat exchanger for actively cooling the terminal. The heat exchanger includes a thermally conductive separator electrically isolating the heat exchanger from the pad of the terminal.

Abstract: A vehicle charging system includes a housing having a mating end for mating with a charging component for the electric vehicle. The vehicle charging system includes a DC charging terminal held in a cavity of the housing and having a mating end for mating with the charging component. The vehicle charging system includes a charging controller for controlling vehicle charging. The vehicle charging system includes an arc sensor in the internal cavity configured to detect an arc event at the mating end of the DC charging terminal. The arc sensor is operably coupled to the charging controller to control the vehicle charging when the arc event is detected.

Abstract: A wire harness for a charging inlet of a vehicle includes first and second high voltage wires having first and second conductors. An inline disconnect electrically connects the first and second conductors and is configured to allow the conductors to be disconnected. The inline disconnect includes a housing having a central cavity, a first chamber at a first end that receives the first high voltage wire, and a second chamber open to the central cavity at a second end that receives the second high voltage wire. First and second disconnect contacts terminated to the conductors are received in the central cavity. A connecting element couples the first and second disconnect contacts and is removable from the disconnect contacts to allow disconnection of the first and second disconnect contacts to electrically separate the first and second high voltage wires.

Abstract: A charging inlet assembly includes a housing extending between a front and a rear. The housing has DC terminal channels and AC terminal channels. The charging inlet assembly includes AC terminals, include a proximity terminal and a ground terminal, received in the corresponding AC terminal channels. The charging inlet assembly includes DC terminals received in the corresponding DC terminal channels. The charging inlet assembly includes a proximity resistor assembly having a plug body holding a resistor, a first resistor conductor and a second resistor conductor. The first resistor conductor is coupled between the resistor and the terminating end of the proximity terminal. The second resistor conductor is coupled between the resistor and the terminating end of the ground terminal.

Abstract: A self-lubricating connector with a housing having a contact receiving cavity with a contact provided therein. A lubricating device is positioned in the housing proximate the contact. The lubricating device extends into the contact receiving cavity and has lubricant provided therein. The lubricant from the lubricating device is deposited or on the outside surface of the contact as the contact is moved between the first position and the second position, reducing wear on the contacts as the contacts are moved between the first position and the second position.

Abstract: A DC charging module for a charging inlet assembly includes a module housing extending between a front and a rear. The module housing has an inner chamber between the front and the rear. The DC charging module includes a terminal having a mating pin at a front of the terminal and a cable connector at a rear of the terminal. The cable connector is located in the inner chamber of the module housing. The mating pin extends forward of the module housing into the charging inlet assembly for mating with a charging connector coupled to the charging inlet assembly. The DC charging module includes a power cable extending into the inner chamber of the module housing to electrically connect to the cable connector of the terminal. The DC charging module includes a heat exchanger received in the inner chamber of the module housing. The heat exchanger is thermally coupled to the cable connector of the terminal.

Abstract: A charging inlet for an electric vehicle includes a housing, a terminal arranged within the housing for engaging with a corresponding mating terminal of a charging plug, and a sensor connectable to a monitoring system of the electric vehicle for detecting the presence of a charging plug installed within the charging inlet.

Abstract: A self-lubricating connector with a housing having a contact receiving cavity with a contact provided therein. A lubricating device is positioned in the housing proximate the contact. The lubricating device extends into the contact receiving cavity and has lubricant provided therein. The lubricant from the lubricating device is deposited or on the outside surface of the contact as the contact is moved between the first position and the second position, reducing wear on the contacts as the contacts are moved between the first position and the second position.

Abstract: A contactor includes a housing defining a cavity. The contactor includes a switch assembly received in the cavity. The switch assembly includes first and second fixed contacts received in the cavity and a movable contact movable within the cavity between a mated position and an unmated position. The movable contact engages the first and second fixed contacts to electrically connect the first and second fixed contacts in the mated position. The switch assembly includes a coil assembly in the cavity operated to move the movable contact between the unmated position and the mating position. The contactor includes a heat transfer device coupled to the housing. The heat transfer device is thermally coupled to the first fixed contact and the second fixed contact to dissipate heat from the first fixed contact and the second fixed contact.

Abstract: A cooling system for a power connector of a charging inlet assembly includes a cooling adapter coupled to a housing of the charging inlet assembly including an adapter body forming a cavity. The cooling adapter includes supply and return ports adjacent a cable exit. The cooling system includes a heat exchanger positioned in the cavity of the cooling adapter including a heat exchanger body configured to receive the power cable and/or the terminal. The heat exchanger body is thermally coupled to the power cable or the terminal to dissipate heat therefrom.

Abstract: A thermal sensing system includes an electrical contact, a sensing element, and at least one position sensor. The electrical contact releasably connects to a mating contact for establishing a conductive path across a mating interface. The electrical contact defines a channel therein that extends from an opening along an outer surface of the electrical contact. The sensing element is at least partially outside of the channel and is configured to move relative to the electrical contact from a first position to a second position based on a temperature increase within the channel that exceeds a designated threshold temperature. The at least one position sensor is spaced apart from the electrical contact and is configured to detect a position change of the sensing element from the first position to the second position, indicating that the temperature within the channel exceeds the designated threshold temperature.

Abstract: A self-lubricating connector with a housing having a contact receiving cavity with a contact provided therein. A lubricating device is positioned in the housing proximate the contact. The lubricating device extends into the contact receiving cavity and has lubricant provided therein. The lubricant from the lubricating device is deposited or on the outside surface of the contact as the contact is moved between the first position and the second position, reducing wear on the contacts as the contacts are moved between the first position and the second position.