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J1772 inlet

by erroneus, published

J1772 inlet by erroneus Feb 24, 2013

Description

I found it extremely annoying that this simple yet very expensive (to buy) thing has not been posted anywhere. So I made my own based on the spec that I found somewhere.
J1772 is a charging standard for electric cars, the inlet is the part that is found on the car, and if you wanted a dummy inlet to simply plug in the charger to hang it up or keep crud out of the pins, be ready to fork out some $$$, but now you can just print it. Feel free to modify and re-post, but please refer to this original. Thanks.
Update 2013-09-08, this part for sale in a couple places around the net. You will notice that the licence agreement you make when you download this indicates it is not for commercial use, that means you cannot sell it if you downloaded it from here. The only person who has authority to sell this particular part is Joel Clemens.
25$ plus shipping, please contact joelclemens at gmail dot com if interested, thank you for your support :) The unit that is being sold DOES have a latch, which is a recent update not fully published here.
Update:
Thurs, Sept 12 2013, Starting to sell a few, I hope I can keep up with demand :-o
I am in Canada, shipping to USA is 8$ ETA about 2 weeks
shipping to UK is 9$ ETA, also about 2 weeks
Tracking and insurance will cost more, but are you really in that much of a hurry?
I have no idea if you will be charged duties/VAT, so you are on your own. (isn't it like that everywhere on the net?)
The email address above is also registered with paypal, thank you kindly :)
Also I am working on an angled version, start with a 25 degree tilt, this version would be 30$ because of the extra time and plastic.
Update 2013-10-03 (unit now available in ABS)
Added a sort-of web store to my blog, to buy this, go here
erroneus.myevblog.com/buy-plastic-parts-here/
Thanks!

Update October 24 2014
I have not been selling this particular model for some time. 3D printing is a very slow process.... cast urethane is quicker, and injection molding is the fastest!
The hooded/hook version of this inlet has been my most popular version, which is now available injection molded!
I am selling on both my blog (above) and ebay here: ebay.com/itm/171514424417

Special thanks to you! the community for making this possible!

Recent Comments

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Thanks for posting Grahm, yes, I do know about the EMW project, and I am working with an individual to create a chademo charger out of it. The main issue with the EMW 12kw charger is that it is not isolated which can be a hazard if you have an exposed pack like in a DIY conversion, or a leaf, a ground fault can brick the car (can drive, but cannot charge) until it is un-bricked at a dealership.
I also come from the DIY EV crowd, so I understand you may not be familiar with the leaf when comparing to a home-built EV.
The leaf has an on-board 3.3kw charger, this is what the j1772 connector goes to. (newer models have a 6kw option). at 240V, the input current cannot go over 16amps with the 3.3kw version. The leaf has another option to use an off-board charger for higher power and faster charging, (up to 50kw), the connection standard for that is a japanese standard called CHAdeMO. Which is why i stress the importance of getting an open source chademo charger.
Hi again Erroneus

I assume you know about the EMW 12-15KW charger from EMotorWerks, although I bought a kit the charger is open source, would this be a good candiate for you basic charge platform, it is controlled by an arduino so nice an easy to modify to your own ends.

Please excuse my naivety here but do Leaf's not have chargers built in, or is the leaf charger external to the car? (i.e. installed at home)

The EMW charger I am just completeing is around the size of a lead acid battery (not as heavy), so potentialy portable and can charge up to 15KW from an AC source (they are currently upgrading it to do up to 30KW with new high power circuit boards), there are several versions available currently, PFC/Non-PFC, Liquid/Air cooled,Single/Three Phase.

there is a great thread on

diyelectriccar.com/forums/showthread.php/10kw-60a-diy-charger-open-source-59210.html

Valery (valerun) is the guy from EMW who is selling the kits, most of the EV enthusiasts on diyelectriccar agree this is the best/cheapest open source charger money can buy (currently).

Anyway it is great to see others using 3D printers for EV development, I salute you ;-)

Graham

PS my alias on diyelectriccar is sexstrap, short for "Sussex Bootstrap", nothing rude ;-) I have made several posts on the charger thread concerning my current charger build.
Thanks for your post Graham.

This inlet doesn't have the locking latch, which is why it wasn't meant for charging, besides, the metal parts are the important part that have to be machined precisely, and I have no idea what the dimensions are supposed to be.

I was going to do the j1772 plug, but I bought some from china. The 3d printer is great, but because of the all the work it takes to get something done from scratch, they are generally only good for things that you cannot buy.

You may be interested in my chademo plug that I just posted yesterday. thingiverse.com/thing:121581

I envision a mobile 17kw charger to enable my Nissan leaf to use the public j1772 charge points that are connected to 90 amp breakers and use their full potential.
If you have the capabilities to get the metal pins for a j1772 port/plug, could you make chademo power pins too? (i already have data pins completed)

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Instructions

Printed with 1.75mm ABS on a Maker Gear Prusa Mendel with sprinter firmware on a glass bed, (don't you just love that glassy finish?). 0.35mm print head and .2mm layer thickness. Object created in Blender, sliced with slic3r and printed with pronterface. Some sanding may be required, I used a dremel, see photos.
Update: 2013-09-21 uploaded version with latch, takes 2 hours and 40 min to print PLA with .3mm layers
Hi Erroneus, love this thing, I am just completing my EV conversion, see blog electrobeatev.blogspot.co.uk/ and after nearly choking at the extortionate price of J1772 plugs & sockets, and seeing as I built my 3D printer just before embarking on my EV build, I thought I would just check on thingiverse for "J1772" and here I am :-)

I see you have covered yourself by stating that this should not be used for charging, however after speaking with an EV expert/friend (he has 7 years+ experience) he and I both agree that if this was printed in 100% ABS at high quality and correctly fitted with bullet plug contacts of the correct type for the J1772 standard that there is no reason why this socket would not be perfectly capable of charging an Electric Car.

In fact I would love to test this theory as I am just completing an open source 12-15KW battery charger from “EmotorWerks”

emotorwerks.com/products/online-store/product/show/7-complete-emw-smartcharge-12000-ev-charger-component-kit-no-enclosure
and will be charging my 10KW Lithium polymer pack with it shortly.

Once I have proven the charger works properly I am going to try charging it through one of these connector sockets if I can find some internal electrical connections of the correct type (this may be difficult however)

I don’t suppose you would be interested in modeling the J1772 plug to add to your collection? If we can make this work (safely) you would become a hero of the EV community ;-)

I guess from this you drive an EV, what is it, did you build it yourself?

Graham
Thanks for your post Graham.

This inlet doesn't have the locking latch, which is why it wasn't meant for charging, besides, the metal parts are the important part that have to be machined precisely, and I have no idea what the dimensions are supposed to be.

I was going to do the j1772 plug, but I bought some from china. The 3d printer is great, but because of the all the work it takes to get something done from scratch, they are generally only good for things that you cannot buy.

You may be interested in my chademo plug that I just posted yesterday. thingiverse.com/thing:121581

I envision a mobile 17kw charger to enable my Nissan leaf to use the public j1772 charge points that are connected to 90 amp breakers and use their full potential.
If you have the capabilities to get the metal pins for a j1772 port/plug, could you make chademo power pins too? (i already have data pins completed)
Hi again Erroneus

I assume you know about the EMW 12-15KW charger from EMotorWerks, although I bought a kit the charger is open source, would this be a good candiate for you basic charge platform, it is controlled by an arduino so nice an easy to modify to your own ends.

Please excuse my naivety here but do Leaf's not have chargers built in, or is the leaf charger external to the car? (i.e. installed at home)

The EMW charger I am just completeing is around the size of a lead acid battery (not as heavy), so potentialy portable and can charge up to 15KW from an AC source (they are currently upgrading it to do up to 30KW with new high power circuit boards), there are several versions available currently, PFC/Non-PFC, Liquid/Air cooled,Single/Three Phase.

there is a great thread on

diyelectriccar.com/forums/showthread.php/10kw-60a-diy-charger-open-source-59210.html

Valery (valerun) is the guy from EMW who is selling the kits, most of the EV enthusiasts on diyelectriccar agree this is the best/cheapest open source charger money can buy (currently).

Anyway it is great to see others using 3D printers for EV development, I salute you ;-)

Graham

PS my alias on diyelectriccar is sexstrap, short for "Sussex Bootstrap", nothing rude ;-) I have made several posts on the charger thread concerning my current charger build.
Thanks for posting Grahm, yes, I do know about the EMW project, and I am working with an individual to create a chademo charger out of it. The main issue with the EMW 12kw charger is that it is not isolated which can be a hazard if you have an exposed pack like in a DIY conversion, or a leaf, a ground fault can brick the car (can drive, but cannot charge) until it is un-bricked at a dealership.
I also come from the DIY EV crowd, so I understand you may not be familiar with the leaf when comparing to a home-built EV.
The leaf has an on-board 3.3kw charger, this is what the j1772 connector goes to. (newer models have a 6kw option). at 240V, the input current cannot go over 16amps with the 3.3kw version. The leaf has another option to use an off-board charger for higher power and faster charging, (up to 50kw), the connection standard for that is a japanese standard called CHAdeMO. Which is why i stress the importance of getting an open source chademo charger.
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