Electronic locking mechanisms are critical components ensuring charging safety for new energy vehicles. To enhance system reliability under complex operational conditions, this study first conducts a systematic evaluation of current reliability performance. By analyzing the mechanism's operating principles and structural characteristics, key factors affecting reliability-such as extreme mechanical loads-are identified. Finite Element Method (FEM) simulation was employed to quantitatively analyze stresses in critical components under typical harsh operating conditions. The original design's safety margin was evaluated using stress intensity factor theory, revealing potential reliability bottlenecks. Based on the evaluation results, a comprehensive optimization plan is proposed, including gear profile modification, lock tongue material upgrade, and proactive motor protection strategies. The effectiveness of the optimization plan is verified through rigorous environmental endurance and mechanical vibration testing, significantly improving the overall reliability metrics of the mechanism.