IEC 62196-3 Vehicle Connector And Plug Mechanical Endurance Test
Equipment For EV Charging
Applied standard & clauses:
IEC 62196-3: 2022 clause 22 and 23.
IEC 62196-1: 2022 clause 22, 23.2, 23.3, fig 15, table 8 and table
9.
Product information:
This test equipment meets the requirements of IEC 62196-3: 2020
clause 22 and 23, IEC62196-1: 2020 clause 22 and clause 23,
IEC60309-1: 2012 clause 20 and clause 21, etc.
It is used to verify whether electrical accessories such as
electric vehicle charging interfaces, industrial plugs,
socket-outlets and couplers can withstand the mechanical,
electrical and thermal stresses that occurred during normal
operation without excessive wear or other harmful effects.
The servo motor drives the mechanism to make the test samples
repeat insertion and withdrawal actions. An external load can be
used for the breaking capacity test. The power on / off time, test
speed, stroke, and angle can all be preset on the touch screen.
Technical Parameters:
| Test Station | Single, can be customized |
| Electrical Control Method | PLC intelligent integrated control, with color humanized touch
screen |
| Drive Mode | Servo motor drive |
| Sample Clamping Method | Mechanical clamping, the position of clamping point can be
adjustable along the 3-axis fixture |
| Linear Stroke | 0-100mm, can be preset (the spacing between test plug and test
socket≥ 50mm) |
| Conduction Time | 0-99.9s, can be preset (electrical contact should be maintained no
more than 4s, no less than 2s) |
| Speed of Insertion and Separation | 0-0.85m/s can be preset, default (0.8±0.1) m/s |
| Test Cycles | 0~999999 cycles, can be preset (A stroke is an insertion or a
withdrawal of a plug or vehicle connector with its mating
accessory. A cycle is composed of two strokes, one for insertion
and one for withdrawal.) |
| Test Frequency | 0-10 cycles/min, can be preset (3.75cycles/min=7.5 stoke/min) |
| Load Power | External, providing standard required voltage, current and power
factor, recommended to work with the load cabinet SN224-300V80A |
| Test Contents | Appliance coupler/charging interface breaking capacity test Appliance coupler / charging interface normal operating life test |
| Detection Function | An open circuit alarm can be realized during testing under load,
and the cycles can be recorded real in time. |
| Safety Protection | Ground protection, short circuit protection |
| Power Supply | Single phase AC220V±10%, 50/60Hz, 10A |
Equipment Dimension & Weight | L 1430mm * W 600mm * H1620mm, approx. 180KGS |
Features:
A vehicle connector and plug mechanical endurance test machine is a
specialized testing equipment used to assess the durability and
mechanical performance of vehicle connectors and plugs. These
connectors and plugs are crucial components in vehicle electrical
systems, providing the interface for electrical connections between
various vehicle components. The mechanical endurance test machine
simulates the repeated mating and unmating cycles that these
connectors and plugs may undergo during vehicle operation. Here are
the key features and components typically found in this test
machine:
Test Fixture: The machine includes a test fixture designed to
securely hold and position the vehicle connector and plug being
tested. The fixture allows for controlled mating and unmating
motions without damaging the connectors or plugs.
Actuation Mechanism: The test machine incorporates an actuation
mechanism that applies repeated mating and unmating cycles to the
connectors and plugs. This mechanism can be programmed to simulate
specific mating forces, insertion and extraction speeds, and cycle
patterns.
Force Measurement: The machine is equipped with force measurement
sensors or load cells to measure the mating and unmating forces
applied during the test. This allows for evaluating the force
required for proper connection and disconnection of the connectors
and plugs.
Displacement Measurement: The test machine includes displacement
measurement devices, such as linear encoders or displacement
transducers, to measure the relative movement or displacement of
the connectors and plugs during the mating and unmating cycles.
Cycle Counter and Timer: The machine is equipped with a cycle
counter and timer to track the number of mating and unmating cycles
completed and measure the duration of the test. This information
helps evaluate the endurance and mechanical performance of the
connectors and plugs over time.
Control System: The test machine incorporates a control system that
allows users to set the desired test parameters, such as force
levels, cycle patterns, and speed. The control system also ensures
accurate and repeatable testing procedures.
Data Acquisition and Analysis: The test machine may have data
acquisition capabilities to record and analyze the test results.
This includes monitoring factors such as mating and unmating
forces, displacements, and any signs of wear or failure observed
during the test.
Safety Features: Safety considerations are implemented in the
machine to protect operators and ensure safe testing procedures.
These features may include emergency stop buttons, protective
enclosures, and safety interlocks.
The vehicle connector and plug mechanical endurance test machine is
crucial for manufacturers and quality control departments to ensure
the reliability and durability of connectors and plugs in vehicle
electrical systems. By subjecting the connectors and plugs to
repeated mating and unmating cycles, this machine helps identify
any weaknesses, wear, or damage that may occur over time. The test
results enable manufacturers to improve the design and materials of
the connectors and plugs, ensuring their long-term performance and
reliability in vehicle applications.
