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

摘要： 针对某款新能源汽车充电口盖无法关闭的高频售后故障，文章通过抽样检测、实车拆 解及合格与故障件对比实验，开展系统性故障排查，精准锁定核心诱因。故障根源为充电口 盖锁止机构执行器弹片组件后仰塑性变形，引发关键装配尺寸超差，导致弹片与滑块滑道接 触异常，锁止结构无法正常啮合完成锁止动作，该类故障占比高达 90%，已成为影响用户体 验、拉高返修率的主要问题。精密检测与力学实验验证显示，故障件弹片中心距尺寸超差为 0.39～0.58 mm，远超设计公差，且弹片接触压力显著不足，无法满足锁止力需求。据此从制 造工艺与材料性能两方面制定改进方案，通过改进自动化取件方式、改进模具结构消除成型 变形，同时提升弹片材料强度与抗形变能力。采用改进方案生产的弹片尺寸合格率显著提升， 将改进后的弹片用于执行器和充电口盖，并安装到实车，经实车验证彻底解决该故障，有效 提升充电口盖系统可靠性，为同类新能源汽车车身附件优化提供技术支撑。

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