openinverter forum

Let's discuss here the pros and cons of self-made CCS connector.
Some cons for the current design are already clear:
- Brass tubes cannot carry more than a few amps
- AC pins are missing
- PLA will be instable at higher temperatures

Wonder if the male side will be printable as well

Everything's printable but this is about the inlet...

The power pins are probably the limiting factor but would need to be tested. With temperature sensors on both pins connected to Foccci this should be fairly safe.
With nickel coated copper it would allow more current

I'm getting to be a bit of a broken record on recommending JLC. They can print in nylon mjf.
https://jlc3dp.com
that should have very good strength and temperature capabilities.

As for the terminals, we should be able to find someone making them for OEMs. Once sourced, add the contacts locking / holding features into the housing if they're not in there already.

printed out of glass filled nylon or PA would be be identical to the stock ccs inlet material.

PLA is not a good idea.

pins have to be available some where!

For the pins maybe you can use pins out of a 63A CEE plug.

https://www.plugsocketmuseum.nl/IEC60309_3.html
pin are 8mm and 67 long

I speak chinese, could help asking chinese suppliers if they sell contacts alone.

A couple weeks ago I had a phone call with someone from Phoenix Contact about their CHARX CCS ports and he told me they don't sell the pins loose. Said it was because the port as a whole is a certified part and they don't want people messing with it. Hopefully someone else will have better luck finding pins for a different brand...

I'm also on the hunt for a 3d model of the male end just to print as a dummy, to make sure the port is accessible in the spot I want to install.

Found some chinese seller are selling a complete unit for around £70, socket + pins, no wires.

Is it really worth printing your own?

I've other one of these for my conversion when I get back onto it one day, it all looked OK quality

raysunwong wrote: ↑Tue Dec 31, 2024 1:02 am Found some chinese seller are selling a complete unit for around £70, socket + pins, no wires.

Do you have an link to share to this?

Tip: use the forum attachments to add pictures. This way they don't get lost when services go down/pictures are removed from accounts etc...

uhi22 wrote: ↑Mon Dec 30, 2024 11:26 am Let's discuss here the pros and cons of self-made CCS connector.
Some cons for the current design are already clear:
- Brass tubes cannot carry more than a few amps
- AC pins are missing
- PLA will be instable at higher temperatures

I would advise against pursuing the development of a DIY CCS connector.
This is one of those things that I would put on the list "Just because it can be done, doesn't mean that it should"
As it is an interface to external devices (public DC chargers), any issues/failures are potentially life threatening or damages which could end up as your liability.

I am not questioning your skills and capabilities, but all the rest DIY makers who would follow this example and do possibly critical compromises on parts and materials in their build process.

Please don't share any design files (at least in this stage), if this is your work

While I don't think it is any more life threatening than anything else we do here, I do agree there is a risk that it sheds bad light on DIY conversions. Just picture one of these melted onto the chargers CCS connector. Then they'd actually have a reason to keep DIY away.
Of course when done properly this won't happen but it can't be guaranteed that everyone will do it properly

Agreed, but it's hard to know how good/bad the one raysunwong shared is and what shortcuts they took (if any..)

jrbe wrote: ↑Tue Dec 31, 2024 12:27 pm how good/bad the one raysunwong shared is

It is the standard "DuoSida" ccs port can be had for that kind of money, in the end if you overload the port you get problems. The biggest issue is the pins + pin to cable contacts that cause heating. If you do not properly have a CCS controller that monitors temps and derates then you need to run it very conservative.

In the grand scheme of costs the HV cables to the charge port will cost more then a second hand charge port with cables. Specially if you need propper pins sized for the cables and current.

J0hannes wrote: ↑Tue Dec 31, 2024 9:05 am Do you have an link to share to this?

Tip: use the forum attachments to add pictures. This way they don't get lost when services go down/pictures are removed from accounts etc...

It’s a chinese market place, here is the link
https://e.tb.cn/h.ThzZPG9tfSvmKaB?tk=Z60VeZmWTfj CZ3458

Even though it is not self made, it is worth mentioning that you can buy brand new CCS connectors from TE at your local electronics distributor for (IMO) a resonable price (315€ incl. VAT): for example: https://www.mouser.de/ProductDetail/TE- ... VW8w%3D%3D

This is the product site from TE: https://www.te.com/en/product-CAT-AQ6-C ... =false&q2=

I shared this in another thread, but for anyone needing a type 1 inlet, there's a great deal on ebay that comes with cables too: https://www.ebay.ca/itm/176408218627

The PE pins of 32A CEE red have the matching diameter and length. Found two different types.

I see a stack of PE-less CEE plugs piling up
I think this solution is legit for DIY V2G installations where you only run like 30A max. On the other hand my CCS plug was less than 100€ on ali.

The "CCS plug" is female. The pins are intended for "low-power" vehicles.

You could put a dot of thermal marking paint on the end of each pin to monitor long term / temp peaks. Gives a nice and easy to see reference.