Xincheng Technology Reveals How to Design an AC Charging Station Control Board for Easy Maintenance and Replacement, Reducing Maintenance Costs and Time?

The design approach provided by Xinrong Technology is a four-component system: "modularization + standardized interfaces + quick-release structure + remote pre-diagnosis." The goal is to achieve on-site replacement in 5 minutes with zero training required, while keeping the maintenance cost per unit at ≤130 yuan. The specific implementation is as follows:

"Nuclear Board - Expansion Board" Two-Part Hardware

• Nuclear Board: MCU + Metering + CP Driver + Communication, 80 mm × 50 mm, with 4 rows of 2.54 mm headers for external connections, all signals at 3.3 V level, hot-swappable without causing board damage.

• Expansion Board: Relay, temperature probe, fan power supply, LED light board, connected to the core board using 20 A plug-in terminals (Phoenix MC 1.5/4-ST-3.5). The terminals come with a built-in latch that can be easily detached by pressing with a finger.

• Result: The after-sales service only replaced the core board (BOM cost 90 RMB), leaving the expansion board inside the chassis to avoid increased contact resistance caused by repeated plugging and unplugging of high-current terminals.

Slide rail + floating screw socket quick-release structure (low-cost)

• 1.2 mm thick "Ω"-shaped sliding rails are pressed on both sides of the housing. The core plate is pushed along the guide rail by 30 mm to reach its correct position;

• The floating screw base (CN218702818U solution) is inserted into any through hole of the card plate, with the backstop automatically locking. It allows a positional error of 1.5 mm, eliminating the need for re-tapping for different-sized card plates;

• The entire replacement process: remove the header pins → push out the old board → push in the new board → insert the header pins, timed at 3 minutes, no screwdriver required.

Color/Dummy Interface

• Use orange for high-voltage terminals, blue for communication, and white for fans/lights;

• Each terminal is equipped with a unique keyway protrusion, preventing incorrect insertion at 180° to avoid on-site misconnections.

Remote pre-diagnosis reduces 50% of unnecessary home visits

• The nuclear board is equipped with a built-in 1 MB circular SRAM, capable of high-speed recording of 48-channel waveforms (V-I-T-CP) for the 30 seconds preceding a fault;

• The 4G-Cat.1 module uploads logs and snapshots to the cloud within 5 seconds of a fault. AI compares over 200 vehicle model curves and provides three-level recommendations: "Replace the mainboard / Replace the expansion board / Replace the gun cable.";

• Engineers bring the necessary accessories for on-site service, reducing the average repair time from 45 minutes to 12 minutes (actual operation and maintenance data).

Firmware OTA Differential Upgrade

• Upgrade package <60 kB, completed in 30 seconds; supports resuming from breakpoints, automatic rollback upon signal interruption, and zero-field flashing.

• Standardized Packaging and Logistics

• The nuclear board is equipped with a unified ESD bubble cover, with a volume of 0.15 L, and can be mailed in a standard envelope at a shipping cost of 8 yuan;

• Old Board Recycling: User scans QR code → Courier delivers → Manufacturer refurbishes → Resale. Recycling price: 40 yuan, further reducing maintenance costs.

Users can DIY replace (for home use, 7 kW)

• Manufacturers such as Jian Siyan have launched DIY nuclear plate kits, complete with 1:1 color wiring diagrams and foolproof terminals. Even car owners with average DIY skills can complete the replacement in just 10 minutes, avoiding the 600-700 yuan cost of a full unit replacement at a 4S shop.

one-sentence summary

• Disassemble the AC charging pile control board into a "quick-release rail board + terminalized extension board," then use remote pre-diagnosis to inform users "which board to bring." On-site replacement can be completed in just 5 minutes with simple manual operations, reducing the maintenance cost per unit to under 130 yuan. This approach saves over 70% in costs and time compared to the traditional "whole pile disassembly and return to factory" model.

The AC charging pile mainboard produced by Xincheng Technology features simple installation, easy maintenance, safety and stability, and high efficiency. Welcome to inquire and purchase!