关键词: 新能源汽车；充电口盖；执行器；弹片变形；故障分析；方案改进

Abstract: Aiming at the high-frequency after-sales failure of unsuccessful closing of the charging port cover for new energy vehicles, this paper conducts systematic fault troubleshooting through sampling inspection, real-vehicle disassembly, and comparative experiments between qualified and faulty parts to accurately identify the core cause. The root failure is the backward plastic deformation of the shrapnel component of the charging port cover locking actuator, which causes the key assembly dimension to be out of tolerance, resulting in abnormal contact between the shrapnel and the slider slideway. The locking structure therefore fails to mesh normally and complete the locking action. This type of failure accounts for up to 90%, which seriously affects user experience and increases vehicle repair rates. Precision detection and mechanical experiments show that the center distance of faulty shrapnel parts exceeds the design tolerance by 0.39~0.58 mm, and the contact pressure of the shrapnel is obviously insufficient to meet the locking force requirements. Accordingly, this paper proposes improvement schemes from the aspects of manufacturing process and material performance. By optimizing the automatic picking process and mold structure, the forming deformation is eliminated, and the material strength and deformation resistance of the shrapnel are improved. The shrapnel manufactured by the improved scheme achieves a significantly higher dimensional qualification rate. The optimized shrapnel is assembled into the actuator and charging port cover for real vehicle verification. The test results prove that the fault is completely eliminated. The research effectively improves the reliability of the charging port cover system and provides technical support for the structural optimization of similar body accessories of new energy vehicles.

Key words: new energy vehicle; charging port cover; actuator; shrapnel deformation; fault analysis; scheme improvement