Charging Interface Test Device for Breaking Capacity and Operation

Charging Interface Breaking Capacity and Normal Operation Test Device

Sample and Limitation:

Test Item: Electric vehicle charging interface, industrial plugs and sockets, and couplers.

Purpose of Test: Used to verify whether the electrical accessories, such as electric vehicle charging interfaces, industrial plugs and sockets, and couplers, can withstand mechanical, electrical, and thermal stresses during normal use without excessive wear or harmful effects. The goal is to validate their reliability.

Test Principle:

The test is conducted using a servo motor-driven mechanism that performs linear insertion and withdrawal actions on the sample, reaching a certain number of cycles. The system automatically rotates the solution, and an external load can be connected to perform on/off tests. The on/off time, test speed, and stroke can all be preset via a touch screen.

Structure and Features:

The structure adopts an integrated frame, driven by a servo motor with precise ball screw and synchronous belt drive. The system is controlled by a PLC with a powerful digital display function and a user-friendly interface on a 7-inch color touch screen. The fixture is three-axis adjustable, suitable for testing the lifetime of charging gun interfaces.

Environmental Conditions:

Power supply: AC220V±10%/50-60Hz, 2kW

Working Temperature: 0-40°C, Humidity: 30%-90%

Dimensions: Approx. W1850*D800*H1700mm

Weight: Approx. 150kg

Technical Parameters:

Test Items	a) Mechanical locking device life test b) Breaking capacity c) Normal operation (service life)
Sample Range	Customized fixtures based on customer samples
Station	Single station
Electrical Control Mode	Mitsubishi PLC intelligent integrated control, 7-inch color human-machine touch interface
Operating Mode	Manual or program-controlled operation
Function	Simulates normal charging interface operation, including charging interface insertion and withdrawal, mechanical locking device unlocking/locking. It can also be tested independently. The system is programmable for test speed, test time, and test cycles, with a single liquid pool and stirring function.
Drive Mode	Servo motor-driven insertion and withdrawal action, electric rotation for solution dipping, assisted by pneumatic cylinders for opening and closing the interlock mechanism.
Sample Fixture and Clamping Method	Mechanical clamping with adjustable X/Y/Z three-dimensional fixtures. The clamping point position is adjustable, and fixtures can be swapped to test national, American and European standard AC/DC charging interfaces.
Automatic Flip	The fixture at the charging gun interface includes an automatic flipping mechanism that can rotate 90º. The dipping time is controllable.
Test Cycles	0~999,999 times, presettable. The system will automatically stop when the preset number of cycles is reached.
Breaking Time	1-999.9 seconds, presettable (Standard requires electrical contact to be maintained no more than 4 seconds and no less than 2 seconds).
Insertion/Withdrawal Rate	0-10 times/min, presettable (3.75 cycles/min, 7.5 strokes/min).
Test Stroke	0-200mm, presettable (Test plug and socket distance ≥ 50mm).
Test Speed	0-850mm/s, directly preset via the touchscreen.
Force Display	Equipped with a 50kg capacity force sensor for real-time force monitoring. A force-time curve can be generated, displaying maximum insertion and withdrawal forces, as well as the current force value. Force range: (0-500)N, with a measurement error of ≤±0.5% F.S., resolution ≤0.1N.
Locking Mechanism	The system includes an automatic pressing function for the mechanical locking device, simulating normal operating conditions.
Solution Tank	A test solution tank containing a mixture of 5% salt and 5% sand (ISO 12103-A4 coarse particulate test dust or equivalent), suspended in distilled water.
Immersion Requirements	Immersion liquid frequency, immersion time, drying time, insertion/withdrawal cycles, and cycle times are all programmable.
External Load	External load can be connected for testing.
Detection Functions	When connected to a load, the system can trigger an open circuit alarm and record the current cycle count.
Safety Protection	Ground protection, short-circuit protection, overload protection.

Sinuo is an innovation manufacturing company, specializing in the research and development and sales of laboratory construction and testing equipment for electrical appliances (covering the construction of energy efficiency and performance laboratories, as well as supplementary waterproof testing laboratories, materials flame-retardant laboratories, basic general testing equipment, etc.), Sinuo aims to provide clients with complete laboratory construction, system integration, R&D, rectification and after-sales service, and strive to be the leader of one-stop service for laboratory construction in the field of electrical appliance testing.

Sinuo  products are composed of all kinds of testing equipments as per standards of IEC/ BS/ EN/VDE/UL/ ISO..., such as household appliances testing equipment, energy efficient testing laboratories and comprehensive performance test system for household appliances, battery testing equipment,  automotive testing equipment, luminaries testing equipment,IP code testing equipment, environmental test chamber, flammability test chambers, EMC testing equipment and etc.

Sinuo employees include a highly trained staff of engineers for sales and service, that are committed to offer satisfactory products and prompt service to all home and abroad customers.

Sinuo cooperate with many research institutions and schools to enable our techincal capacities. Sinuo has two own factories, one is in Guangzhou, the other is in Dongguan, and authorized agents and representative offices in Korea, South Africa, Egypt,Pakistan and Philippines.

Sinuo combines all the R/D and production advantages, contributes to provide perfect, high-end and systematic electrical appliance testing laboratory solutions, products and services for corporate customers, universities and third-party laboratories. Our clients include Bureau Veritas, CSA, Intertek, TUV Rehiland, TUV SUD, SGS, etc.