We claim:
1. A charging gun (100), comprising:
a plug assembly (102) located at a first side of the charging gun;
5 a power cable (110) extending from a second side of the charging gun; and
a plurality of charging pins (104) that are housed within the plug assembly, each charging pin
comprising:
a lug (106) that is crimped to the power cable; and
a power terminal (108) that is replaceable, wherein the lug and the power terminal are:
10 engaged with each other to achieve full surface contact; and
secured to each other using a securing means (116/120).
2. The charging gun as claimed in claim 1, wherein:
the lug and the power terminal are parallel to each other, and
15 the lug comprises:
at least one side extension (1066A/1066B); and
the power terminal comprises:
fastening threads (1082) on its outer surface; and
the securing means comprises a fastening bush (116) at the lug, the fastening bush comprising:
20 a hollow end (1162) for receiving the power terminal;
a closed end (1164), the inner surface of the closed end being pressed against by the at
least one side extension of the lug; and
fastening threads (1166) on the inner surface of the fastening bush, wherein the fastening
threads of the fastening bush contact the fastening threads of the power terminal.
25
3. The charging gun as claimed in claim 2, wherein:
the lug further comprises:
a first end (1062) in the form of a protrusion; and
a second end (1064) crimped to the power cable; and
30 the power terminal further comprises a depression for receiving the first end of the lug.
4. The charging gun as claimed in claim 2, wherein:
the fastening bush is made of steel or a copper alloy; and
the power terminal is made of a copper alloy or an aluminium alloy.
5 5. The charging gun as claimed in claim 1, wherein:
the lug comprises a first end having two flat projections (1062A/1062B), wherein the two flat
projections are spaced apart from each other at a distance to create a space in between the two
flat projections; and
the power terminal comprises a flat projection (1081) at one end, wherein the space in between
10 the two flat projections of the lug is used to receive the flat projection of the power terminal,
such that the two flat projections of the lug sandwich the flat projection of the power terminal.
6. The charging gun as claimed in claim 5, wherein the securing means comprises at least one
screw (120) that fastens the two flat projections of the lug to the flat projection of the power
15 terminal via at least one hole on each of the two flat projections of the lug and the flat projection
of the power terminal.
7. The charging gun as claimed in claim 5, wherein:
the lug is made of sheet metal; and
20 the power terminal is made of a copper alloy or an aluminium alloy.
8. A method (500) of replacing a power terminal (108) in a charging gun (100), comprising:
separating (502) a plurality of charging pins (104) from a plug assembly (102) of the charging
gun, wherein each charging pin comprises the power terminal and a lug (106) crimped to a
25 power cable (110), and wherein the lug and the power terminal are:
engaged with each other to achieve full surface contact; and
secured to each other using a securing means (116/120),
replacing (504) the power terminal of the charging pin by:
detaching the power terminal from the lug of the charging pin; and
30 connecting a second power terminal (108A) to the lug; and
securing (506) the second power terminal to the lug using the securing means.
9. The method as claimed in claim 8, wherein:
the lug and the power terminal are parallel to each other; and
the lug comprises:
5 at least one side extension (1066A/1066B); and
the power terminal comprises:
fastening threads (1082) on its outer surface; and
the securing means comprises a fastening bush (116) at the lug, the fastening bush comprising:
a hollow end (1162) for receiving the power terminal;
10 a closed end (1164), the inner surface of the closed end being pressed against by the at
least one side extension of the lug; and
fastening threads (1166) on the inner surface of the fastening bush, wherein the fastening
threads of the fastening bush contact the fastening threads of the power terminal.
15 10. The method as claimed in claim 9, wherein:
the lug further comprises:
a first end (1062) in the form of a protrusion;
a second end (1064) crimped to the power cable; and
the power terminal further comprises a depression for receiving the first end of the lug.
20
11. The method as claimed in claim 9, wherein:
the fastening bush is made of steel or a copper alloy; and
the power terminal is made of a copper alloy or an aluminium alloy.
25 12. The method as claimed in claim 8, wherein:
the lug comprises a first end having two flat projections (1062A/1062B), wherein the two flat
projections are spaced apart from each other at a distance to create a space in between the two
flat projections; and
the power terminal comprises a flat projection (1081) at one end, wherein the space in between
30 the two flat projections of the lug is used to receive the flat projection of the power terminal,
such that the two flat projections of the lug sandwich the flat projection of the power terminal.
13. The method as claimed in claim 12, wherein the securing means comprises at least one screw
(120) that fastens the two flat projections of the lug to the flat projection of the power terminal
via at least one hole on each of the two flat projections of the lug and the flat projection of the
5 power terminal.
14. The method as claimed in claim 12, wherein:
the lug is made of sheet metal; and
the power terminal is made of a copper alloy or an aluminium alloy