GB/T 32879-2025Swappable battery pack connector of electric vehicle (English PDF)

3.1 Swappable Battery Pack Connector

A connection device used to connect a swappable battery pack to the vehicle body or charging rack, facilitating the transmission of electrical energy, electrical signals, communication data, and thermal media.

NOTE. Electrical connectors and fluid connectors are included.

3.2 Connector Plug

The part of the swappable battery pack connector that connects to the battery pack.

3.3 Connector Socket-Outlet

The fixedly installed part of the swappable battery pack connector that connects to the electric vehicle or the battery pack rack at the battery-swapping station.

4.1 The rated operating voltage and rated operating current of electrical connectors should

comply with the provisions of Table 1.

4.2 The rated operating flow rate of fluid connectors should comply with the provisions of Table 2.

Table 2 -- Preferred Values for Rated Operating Flow Rate

6.1 Interchangeability Requirements for Electrical Connectors

6.1.1 Electrical connectors of the same type should be interchangeable.

6.1.2 The performance of interchangeable electrical connector combinations shall meet the

requirements of Clause 7.

6.1.3 High-voltage interfaces shall feature 360° annular shielding; this is not required for

dedicated electrical connectors used for conductive connections between charging racks.

6.1.4 Low-voltage interfaces should support two CAN (Controller Area Network) signal

channels—specifically, Charging CAN and Power CAN—with the option to extend to include Diagnostic CAN, etc., as required.

6.1.5 Low-voltage interfaces shall include a terminal for connection status feedback signals.

6.1.6 Low-voltage interfaces should include reserved expandable pins to facilitate compatibility

and expandability.

6.2 Interchangeability Requirements for Fluid Connectors

6.2.1 Fluid connectors of the same type should be interchangeable.

6.2.2 The performance of interchangeable fluid connector combinations shall meet the

requirements of Clause 7.

6.2.3 The opening travel of the internal valve mechanism within the connector shall be consistent, and the valve core sealing method should be radial sealing.

6.2.4 Based on the spring force values involved in the interaction. The force required to fully open the valve mechanism shall be <=200 N (single-channel), and the activation force for the Z- axis floating spring shall be >=350 N.

6.2.5 The cooling medium shall consist of 50% ethylene glycol and 50% water, with all other specifications remaining the same.

6.2.6 The materials used for the fluid connectors shall not undergo chemical reactions with the cooling medium.

7.1 Structural Requirements

7.1.1 Structural requirements for electrical connectors

7.1.1.1 Terminals and surfaces of the electrical connector shall be free from burrs, flash, and similar sharp edges.

7.1.1.2 Insulating liners, partitions, and similar components shall possess sufficient mechanical

strength and be secured to the housing or body; they shall also comply with the following provisions.

a) Vulnerable insulating components shall be capable of being removed and replaced;

b) They shall be designed so that they cannot be installed in an incorrect position.

7.1.1.3 Terminal positions and protective grounding terminals shall be clearly marked.

7.1.1.4 During the mating process, the sequence of contact engagement shall be ensured as follows. guide pin -> protective grounding -> high-voltage positive and negative terminals -> low-voltage power supply and signals -> interlock; the unmating process shall be the reverse of the mating process.

7.1.1.5 Cables and their connections shall comply with the following provisions.

a) Cables and connections for electrical connectors shall not interfere with the normal operation of the floating follow-up mechanism;

b) After the electrical connector plug, socket-outlet, and cable are correctly connected, there shall be no risk of accidental contact between terminals of different polarities or between terminals and other metal parts;

c) External cables shall be provided with appropriate protective measures.

7.1.1.6 Grounding measures shall comply with the following provisions.

a) Exposed conductive parts of the electrical connector shall have a grounding terminal;

b) After the electrical connectors are mated, the resistance of the protective grounding circuit shall not be greater than 0.1 ohm, and its overcurrent capacity shall meet the requirements of Table 3.

Table 3 -- Cross-Sectional Area of Protective Conductors

7.1.1.7 Electrical connectors should preferably feature a temperature detection function for

power terminals.

7.1.1.8 For electrical connectors used in commercial vehicles where the battery-swapping

system assembly is mounted behind the cab. Applications involving a combination of four connectors shall comply with the provisions of Appendix A; applications involving a single connector shall comply with the provisions of Appendix B; other configurations are detailed in

7.1.1.9 Configuration types for passenger vehicle electrical connectors are detailed in

Appendices D to H.

7.1.2 Structural requirements for fluid connectors

7.1.2.1 The surface of the fluid connector shall be clean and free of debris, with no significant burrs, flash, or similar sharp edges; the inlet/outlet lines and connectors shall be free from deformation that would impair function or assembly.

7.1.2.2 Protective measures shall be applied to the inlet/outlet lines and main body connections of the fluid connector to prevent the ingress of foreign matter into the internal cavities—which could compromise the seal—during transportation and storage.

7.1.2.3 The fluid connector shall be equipped with a mounting panel and corresponding hole patterns to facilitate rapid installation and fastening.

7.1.2.4 The fluid connector shall not have a self-locking function; upon mating, the spring force is transmitted to the mating component’s mounting plate, which must possess sufficient load- bearing capacity.

7.1.2.5 The fluid connector shall be designed with left-right symmetry, featuring identical flow

channels for both the left and right components; the inlet and outlet are interchangeable, enabling “blind assembly” (assembly without visual alignment).

7.1.2.6 After installation, appropriate protective measures shall be implemented around the

fluid connector to prevent the adhesion of mud or sand, which could compromise the seal.

7.1.2.7 The fluid connector lines shall be flexible; neither the lines nor their connections shall interfere with the normal operation of the floating follow-up mechanism.

7.1.2.8 See Appendix I for the configuration types of fluid connector assemblies for commercial vehicles.

7.1.2.9 See Appendices J to L for the configuration types of fluid connector assemblies for passenger vehicles.

7.2 Guide Float Requirements

7.2.1 The connector shall feature an alignment and lead-in function, capable of automatically

correcting positional misalignment during mating to ensure accurate connection. For electric passenger vehicle guidance mechanisms, the axial alignment must be capable of correcting an angular deviation of at least 1° and provide a floating capability of at least ±3 mm in the X/Y/Z direction; for electric commercial vehicle guidance mechanisms, the axial alignment must be capable of correcting an angular deviation of at least 1° and provide a floating capability of at least ±5 mm in the X/Y/Z direction.

7.2.2 The connector socket-outlet shall be equipped with a floating follow-up mechanism; when

the connector plug disengages from the socket-outlet, the socket-outlet—having shifted in the direction of the plug’s movement—shall automatically return to its original position, with a reset deviation of no more than 1.5 mm.

7.3 Degrees of Protection

When the connector plug and socket-outlet are mated, the degrees of protection shall be no lower than the IPX7 and IPX9K requirements specified in GB/T 30038-2013.

7.4 Vibration and Shock

Testing shall be conducted in accordance with 8.5.During the test, the duration for which the contact resistance of the electrical connector terminals continuously exceeds 7 ohm shall not exceed 1 µs. After testing, the electrical connector shall exhibit a good appearance and meet the requirements of 7.3, 7.9, and 7.12; no mechanical performance requirements apply to the electrical connector socket-outlets used at the station. The fluid connector shall exhibit a good appearance and meet the requirements of 7.7.

7.5 Service Life

The mating/unmating durability of the connector shall be at least 10 000 cycles, and it shall meet the requirements of 7.3, 7.7, 7.9, and 7.12.

7.6 Flow Resistance

The flow resistance of the fluid connector shall meet the requirements of Table 4. ......