Product Overview
(1) Overview
This equipment complies with the test requirements of Clause 10.3 of Standard GB/T18487.1-2023, Clause 7.22 and Clause 7.23 of Standard GB/T 20234.1-2023, Chapters 22 and 23 of IEC 62196-1: 2022, and Chapter 8.2.3 of IEC EN 62752-2018. It is suitable for the life test and normal operation test of the disconnection capability of various types of electric vehicle charging connectors.
(2) Equipment Functional Index Requirements
This device is suitable for conducting the plug-in and plug-out life test, plug-in and plug-out force, breaking capacity, and normal operation test for a charging gun charging base. Before the plug-in and plug-out, it can automatically immerse the sample in three different solutions. The testing machine uses servo motors, linear modules, and cylinders as power sources, and uses small fixtures to hold the sample. The computer and imported programmable controller (PLC) serve as the control center. It can hold the charging gun, automatically immerse the charging gun in rain acid solution, salt water solution, and muddy water solution for a period of time, then automatically take it out and insert it into the charging gun base. After that, it is powered on for 1.5 hours, and this process is repeated to simulate the plug-in and plug-out life of the charging gun in the outdoor environment.
(3) Usage Environment
| 1 | Ambient Temperature | 5～35℃ |
| 2 | Ambient Humidity | 85%R.H 25℃ |
| 3 | Atmospheric Pressure | 86～106 Kpa |
| 4 | Environmental Conditions | The equipment site must be free from strong vibrations, intense electromagnetic interference, high concentrations of dust or corrosive substances, direct sunlight, or other direct heat sources. |
| The equipment should be placed horizontally in a well-ventilated test room. There should be enough space around for operation and maintenance |
Main Technical Parameters
| Serial Number | Technical Parameters |
| 1 | Drive Device: linear module, cylinder, servo motor |
| 2 | Controller: The system operates using an industrial computer of 15 inches or larger and an imported programmable logic controller (PLC) with intelligent control capabilities. All test parameters can be stored and can be directly retrieved for reuse. |
| 3 | Can be connected to external power supply and load, capacity range ( 1.1x rated voltage, rated current ), power supply and load users Bring your own. |
| 4 | Can test the following products Can satisfy all 2p+E, 3P+E, 3P+E+N And other specifications of products. AC rated current ≥90A or DC ≥ 250A Vehicle plug and socket product testing. DC air cooling ≥1500V, 250A Vehicle plugs, sockets and other product testing, DC liquid cooling of ≥ 1500V, 800A, and cooperating with the liquid cooling device test bench to dissipate heat for the gun heads. GB /T 20234.2-2015 AC socket (plug), GB /T 20234.3-2023 DC socket (plug), GB /T 20234.4-2023 Super fast charging DC socket (plug). |
| 5 | Motion speed: 0.1–0.8 m/s, adjustable to meet the standard requirement of 0.8 ± 0.1 m/s. Electrical contact shall be maintained for no more than 4 seconds but no less than 2 seconds. |
| 6 | Testing Rate: The rate at which plugs or connectors are inserted into and removed from sockets or appliance input sockets shall be ≥ 7.5 cycles per minute (adjustable). |
| 7 | Manual adjustment ;The system is equipped with a manual adjustment button to facilitate the clamping of the sample |
| 8 | Locking Hook Button Press Test: There are two modes. One involves pressing and holding the button before drawing the gun, then releasing it after drawing. The other requires continuously holding the button down without releasing. |
| 9 | Drive system: The servo motor drives the ball screw to rotate and the silent slide rail is used as a guide to make the fixture Left and right reciprocating motion, can provide ≥500N The clamp has a rotation function, which can place the sample vertically. into the solution. |
| 10 | Insertion and extraction stroke: 0~400 mm arbitrarily set, resolution 0.1 mm: |
| 11 | Insertion and extraction force: ≥500N, high-precision digital pressure module, Computer curve display, there is a report showing the insertion and extraction force values. |
| 12 | Each force value can be stored in a table format for viewing |
| 13 | Fixture spacing: ≥150mm |
| 14 | Fixture base: On both the upper and lower sides, one linear slide rail is installed on each side, which can ensure the straightness of the fixture during operation and the strength of the guiding structure. |
| 15 | Can hold national standard DC charging gun and charging gun holder, providing 6 Different sets of fixtures |
| 16 | Gun clamp: clamp on both sides |
| 17 | Reserved gun line length 1.2 meters, bendable, wiggle room; |
| 18 | The equipment enables the charging gun to rotate and move into different liquid tanks for soaking. The charging gun automatically immerses in different solutions, with four solution tanks provided. |
| 19 | Testing Station: 1 Station Independent |
| 20 | Number of tests: 1~999999 The machine can be set arbitrarily and will stop automatically when the count reaches the set value |
| 21 | Product soaking time: 1~9999s Configurable; |
| 22 | Charging gun insertion time: 1~9999s, adjustable |
| 23 | During load testing, alarm detection is enabled: Adhering to the principle of “conductive when it should be conductive, non-conductive when it should be non-conductive,” the system determines whether the test sample is damaged based on the logical relationship between “position and current.” When damage occurs to the tested sample, the equipment emits an audible and visual alarm and automatically shuts down. |
| 24 | Test Procedure: Automatically immerse the nozzle tip in a bucket containing rainwater acid solution for 4–5 seconds, then remove it and perform 10 automatic insertion/removal cycles. Next, automatically immerse the nozzle tip in a bucket containing saline solution for 4–5 seconds, then remove it and perform 10 automatic insertion/removal cycles. Next, automatically immerse the tip into a bucket containing turbid water solution for 4–5 seconds. Remove and let it air dry for 10 minutes or until naturally dry, then perform 10 automatic insertion/removal cycles. Next, power on the tip and base for 1.5 hours. Repeat steps a–d 20 times. This test procedure is automatically performed by the equipment. |
| 25 | Earth leakage protection: Install an earth leakage circuit breaker at the control power supply inlet of the equipment. In the event of an earth leakage, it will cut off the control power supply, de-energizing the entire cabinet. |
| 26 | Overcurrent protection: Each workstation is protected by a fuse (circuit breaker) to prevent overcurrent or short circuit. |
| 27 | Overload protection: The device is equipped with a circuit breaker that automatically trips when an overload occurs; |
| 28 | Door Safety Protection: All active cabinet doors are equipped with safety switches. When a door is opened, the power supply automatically shuts off to prevent operators from receiving electric shocks. |
| 29 | Emergency Stop Switch: The power cabinet control panel features an emergency stop switch, enabling operators to cut off the power cabinet's output power supply in case of abnormalities or when necessary. |
| 30 | Inlet and outlet leads: The input and output lead ports are covered with protective rings to prevent the cables from being damaged; |
| 31 | Testing of spring-loaded covers or other non-automatically opening protective devices: During testing, the spring-loaded cover shall be tested in both fully open and fully closed positions. The number of opening cycles may be set between 0 and 99999. |
Panel Description
1. Touch screen control: setting parameters and monitoring
2. Turn left button: Turn the gun left
3. Right turn button: The gun turns right
4. Left and right zero point buttons:
5. Start button: machine running
6. Stop button: The machine stops working
7. Power switch: Switchboard power switch
8. Forward button: Press the gun head clamp to move forward
9. Back button: Press the gun head clamp to move back
10. Front and rear zero position:
11. Manual cylinder:
12. Emergency stop switch: emergency shutdown
13. USB Port: connect keyboard, mouse, USB flash drive, etc.
14. Lowering Cylinder: Pressing Cylinder
15. Charging Gun Holder Sample Installation
16. Charging gun tip fixture
17. 4 Liquid tanks (pour different solutions)
18. Gun mount terminal: connect to L1 and L2
19. Slide Handwheel: Vertical Fixture Adjustment
20. Slide Handwheel: Horizontal Fixture Adjustment
21. Power input leakage switch
22. Gas source input: connected to the air pipe
23.Aviation connector
24. Power input: Connect to power supply
25. External load
26. Load terminal: AC connected to L1, L2, L3; DC connected to DC+, DC-
27. Load input terminal: AC connected to L1, L2, L3; DC connected to DC+, DC-
Operation Instructions
(1) Device Connection
• Power connection: Find the power interface on the side of the device and connect it to an external AC220V control power supply to provide power support for the device's electrical system and ensure the normal operation of the device's internal electronic components, control system, etc.
• Gas source connection: Connect the gas source interface of the equipment to the external gas source. The gas source pressure is required to be between 0.4 and 0.6 MPa.
(2) Device Startup
• On the device control panel, locate and press the “Power Switch.” After pressing the switch, the device begins to power up and start. The operator can then access the device's operating interface by tapping the screen to configure specific test settings and review operational precautions.
(3) Enter the Parameter Setting Interface
• After the device touch screen enters the initial screen and clicks to enter, find and click the "Parameter Monitoring " interface option to enter this interface.
1) Timing: Display test time
2) Count: Displays the total number of tests
3) Reset: reset the number of tests to zero
4) Plug and unplug: Display the current plug and unplug stroke (mm)
5) Rotation: Displays the current rotation angle of the charging gun (degrees)
6) Display force: Display real-time insertion force or extraction force (N)
7) Reset: reset the displayed force value to zero
8) Maximum insertion force: the maximum instantaneous force value of insertion (N)
9) Maximum extraction force: Maximum instantaneous extraction force (N)
10) Soaking container 1: Display the current container 1 Soaking times
11) Soaking container 2: Display the current container 2 Soaking times
12) Soaking container 3: Display the current container 3 Soaking times
13) Soak container 4: Display the current container 4 Soaking times
14) Reset button: reset the current container soaking times
15) One-touch reset button: clear all data
16) Reset button: clear alarm information
17) Light button: Turn the device light on or off
18) Alarm information: Display device alarm information
(4) Enter the touch screen "Parameter Setting" interface : This interface sets the corresponding options of relevant test parameters
1) Insertion and removal speed: Set the speed of insertion and removal (mm/s)
2) Insertion and extraction stroke: Set the insertion and extraction stroke MM (mm)
3) Rotation speed: Set the speed of the charging gun rotation (degrees/second)
4) Rotation angle: Set the rotation angle of the charging gun (degrees)
5) Insertion time: The time for charging gun to be inserted can be set from 1 to 999.9 seconds (seconds)
6) Unplug time: The time for unplugging the charging gun can be set from 1 to 999.9 seconds (seconds)
7) Electromagnetic lock power-on time ; set the electromagnetic lock power-on time (s)
8) Threshold switch : When on, the alarm will sound after the door is opened ; when off, the alarm will not sound after the door is opened
9) Load switch: When turned on, the load is connected ; when turned off, the load is disconnected
10) L1 detection: L1 current detection switch
11) L2 detection: L2 current detection switch
12) L3 detection: L3 current detection switch
13) DC Current Detection : DC Current Detection Switch
14) Electromagnetic interlock switch
15) Electromagnetic lock feedback polarity switch
16) Automatic push button switch
(5) Sample installation
1) Gun Tip Fixation
• Place the sample gun tip on the gun tip holder and keep it level and secure by adjusting and using fixing devices (such as screws, clamps, etc.). This step ensures that the gun tip does not shake or tilt, otherwise it will affect the accuracy of subsequent plug-in and pull-out tests.
2) Debug Mode Operation and Cylinder Adjustment
• After entering the debugging mode, select the "Button" button on the touch screen and press the button on the panel. This series of operations is to activate the control functions related to the button cylinder.
• Adjust the button cylinder bracket and slowly move the button cylinder so that the front end of the cylinder can accurately press the gun button into place. During the adjustment process, carefully observe the pressing situation to ensure that the button is triggered normally. After the adjustment is appropriate, secure the cylinder bracket to prevent it from moving during subsequent operations.
3) Gun Mount Fixation and Preliminary Alignment
• Secure the gun mount to the gun mount bracket, ensuring it is secure. Then, select "Slow" on the touch screen and press the "Forward" button on the panel. The gun tip will now move toward the gun mount at a slower speed.
• When the gun tip is about to approach the gun mount, carefully observe the gap between the gun mount and the gun tip. This step is to determine whether the relative position of the two is appropriate, which provides a basis for subsequent precise adjustment.
4) Precise alignment and final fixation
• Adjust the gun mount bracket based on the observed gap. By fine-tuning the positions in these three directions, the gun tip can be evenly and symmetrically aligned with the gun mount. During the adjustment process, constantly observe the relative position of the gun tip and the gun mount, and repeatedly fine-tune until the alignment is ideal. After confirming that the alignment is correct, tighten the gun mount screws to completely fix the gun mount position and prepare for the formal plug-in test.
(6) Three-phase load resistance and three-phase load voltage are connected
1) Three-phase load resistance connection
• Locate the "Three-Phase Load Resistor Input" port on the back of the device and connect the external resistor. Ensure the port is securely connected to prevent loose connections that could affect test results. Also, ensure that the external resistor's specifications meet test requirements. For example, parameters such as resistance value and wattage should match the device's test standards.
2) Three-phase load voltage access
• Locate the “Three-Phase Load Voltage Input” interface on the side of the equipment and connect it to an external voltage source. During connection, strictly adhere to electrical safety regulations to ensure the voltage source's voltage level, frequency, and other parameters match the equipment requirements. Avoid connecting mismatched voltages that could damage the equipment. Simultaneously, verify that all connections are secure to prevent safety hazards such as leakage or short circuits.
(7) Zero point determination
1) Insert zero point determination
• Press the "Forward" button on the control panel to move the gun tip toward the gun holder. Once the gun tip is properly inserted into the gun holder (a proper position typically means the gun tip and gun holder are properly connected without excessive squeezing or looseness), press the "Reset" button or the "Confirm Zero" button on the control panel. The travel indicator will change to 0 mm, confirming the zero position of the gun tip.
2) Pull-out stroke record and zero point determination
• Press the "Back" button on the control panel to remove the gun tip from the gun holder. When the gun tip is removed to the desired position (the desired position means the gun tip is completely free of the gun holder and at the end of the test), record the current stroke displayed. Next, press the "Reset" button or the "Zero Point Confirmation" button on the control panel again to reset the stroke display to zero, completing the zero point determination for the removal operation. This will return to the parameter setting screen.
3) Travel data input
• In the parameter settings interface, locate the “Insertion/Extraction Stroke” input field and accurately enter the previously recorded stroke display data into this field. After inputting the data, ensure its accuracy to prepare the parameters for subsequent testing.
(8) Enter the touch screen "Manual" interface:
1) Container 1: Container 1 Press the manual button to raise or lower the car, and the up and down position lights will light up.
2) Container 2: Container 1 Press the manual button to raise or lower, and the up and down position lights will light up.
3) Container 3: Container 1 Press the manual button to raise or lower the car, and the up and down position lights will light up.
4) Container 4: Container 1 Press the manual button to raise or lower the car, and the up and down position lights will light up.
5) Plug and Unplug: Current plug and unplug travel distance data
6) Plug and Unplug Confirmation Zero Point: the plug and unplug position is displayed as 0
7) Rotation: Manually set the rotation angle (degrees)
8) Rotate to confirm zero point: the rotation position is displayed as 0
9) Container Movement [ left ] : The container moves to the left when pressed, and the left position light turns on.
10) Container Movement [ right ] : The container moves to the right when pressed, and the right position light turns on.
11) Container Movement [ front ] : The container moves forward when pressed, and the front position light turns on.
12) Container Moves [ backward ] : Press the button to move the container backward, and the rear position light will turn on.
13) Manually Connect the Load: Set to manually connect the load
14) Test Mode: Test mode is test mode
15) Debug Mode: Set the mode to debug mode
16) Manual speed of fixture: divided into three gears, creeping, slow and fast. When moving manually, it will run at the set gear.
(9) Soaking Parameters
1) Total number of insertions : Set the total number of insertions
2) Dry insertion times : Set the number of insertions without soaking
3) Soaking times for container 1: Set the soaking times for container 1
4) times for container 2 : Set the soaking times for container 2
5) Soak container 3 times : Set the number of soaking times in container 3
6) times for container 4 (spare): Set the soaking times for container 4
7) Number of insertions after soaking : Number of operations of soaking first and then inserting
8) Power-on time : Set the power-on time
9) Soaking time : Set the soaking time
10) Drain time : Set the drain time
(10) Enter the touch screen "plugging force curve" interface: display, collect and process plugging force waveform data
1) Clear waveform: Clear data
2) Pull-out force: Displays the size of the pull-out force
3) Collection: Collect data
4) Save waveform: Save the test data
