IEC 62196-1: 2022 Electric Vehicle Non-Rewirable Accessories
Flexing Test Apparatus With Load
Product Overview:
The flexibility testing apparatus is designed and manufactured
according to requirements of IEC62196-1: 2022 clause 26.4 figure
20, IEC60309-1: 2012 clause 24.4 figure 9, etc. It is used to
process the mechanical load flexing test of the vehicle plugs,
socket-outlets and couplers non-rewireable accessories.
The equipment adopts PLC control and operated by 7-inch colour
human-machine interface, uses a servo motor to control the flexing
angle. The flexing angle, flexing speed and the test cycles can be
preset on touch screen. The test is automatically carried out
according to the set parameters. When the test times reach the
preset number of test times, the device automatically stops and
gives the test completion signal prompt. The test equipment has the
advantages of high-precision digital display, high-efficiency
digital frequency conversion, precise speed adjustment, six-digit
memory setting, multi-function modular fixture, rotating center
centering measuring tool, and built-in load which can supply load
voltage to test sample during test.
The electric vehicle non-rewirable accessories flexing test
apparatus is a specialized testing equipment used to assess the
durability and performance of non-rewirable accessories in electric
vehicles. These accessories may include cables, connectors,
harnesses, or other electrical components that are permanently
attached to the vehicle and cannot be easily disconnected or
rewired. The flexing test apparatus simulates the repeated flexing
and bending motions that these accessories may undergo during
vehicle operation. Here are the key features and components
typically found in this test apparatus:
Test Fixture: The apparatus includes a test fixture designed to
securely hold and position the non-rewirable accessory being
tested. The fixture allows for controlled flexing and bending
motions without damaging the accessory.
Motorized Flexing Mechanism: The flexing test apparatus
incorporates a motorized flexing mechanism that applies repetitive
flexing or bending motions to the non-rewirable accessory. This
mechanism can be programmed to simulate specific flexing patterns,
such as continuous bending or cyclic flexing motions.
Flexing Angle Adjustment: The apparatus allows for adjusting the
flexing angle to simulate various operating conditions or specific
requirements. This ensures that the accessory is tested under
relevant flexing angles that it may experience in real-world usage.
Force and Speed Control: The flexing mechanism includes controls to
adjust the force and speed of the flexing motion. This allows for
mimicking different levels of stress and flexing rates that the
accessory may encounter during vehicle operation.
Cycle Counter and Timer: The apparatus is equipped with a cycle
counter and timer to track the number of flexing cycles completed
and measure the duration of the test. This information helps
evaluate the accessory's endurance and performance over time.
Safety Features: Safety considerations are implemented in the
apparatus to protect the operators and ensure safe testing
procedures. These features may include emergency stop buttons,
protective enclosures, and safety interlocks.
Data Acquisition and Analysis: The flexing test apparatus may have
data acquisition capabilities to record and analyze the test
results. This includes monitoring factors such as flexing angles,
applied forces, electrical continuity, or any signs of wear or
failure observed during the test.
The electric vehicle non-rewirable accessories flexing test
apparatus is crucial for manufacturers and quality control
departments to ensure the reliability and durability of
non-rewirable electrical components in electric vehicles. By
subjecting the accessories to repeated flexing motions, this
apparatus helps identify any weaknesses, fatigue, or damage that
may occur over time. The test results enable manufacturers to
improve the design and materials of the accessories, ensuring their
long-term performance and safety in electric vehicle applications.
Technical Parameters:
| Test Station | Single |
| Electrical Control Method | PLC intelligent integrated control, 7-inch humanized touch
interface operation |
| Drive Mode | Servo motor |
| Sample Clamping Method | Mechanical clamping, the position of clamping point is adjustable |
| Flexing Angle | 0-360° can be adjusted freely (default 90°, 45°on either side of
the vertical) |
| Flexing Rate | 0-60 cycles / min, can be preset |
| Flexing Cycles | 0~999999 can be preset, default 20000 cycles |
| Load Weights | 20N, 25N, 50N, 75N, 100N |
| Load Power | Built-in, with adjustable voltage between conductors 0-250V and
current AC0-400A adjustable |
| Test Judgment | Judging by the signals given when the current is conducted or not |
| Equipment Dimensions & Weight | L 850mm *W 800mm *H 1500mm, the whole machine is about 200Kg |
| Power Supply | Three phase AC380V±10%, 50Hz/60Hz |
Common Faults and Treatments:
| No. | Fault | Reason | Treatment |
1 | Turn on the POWER switch, but the indicator light not turn on | The external power supply is not connected | Please connect to the external power supply |
| The fuse is broken | Find out the reason and change the fuse. |
| The indicator light damaged | Replace the light |
2 | Turn on the POWER switch, Touch screen not work | The internal DC24V power supply is in problem | Replace the DC24V power supply |
| Touchscreen damaged | Replace the touchscreen |
| 3 | Touch screen no response | Connection to PLC loose | Reconnect |
| Touchscreen damaged | Replace the touchscreen |
| 4 | Load power no power supply | Load socket damaged | Replace the socket |
| The fuse is broken | Change the fuse |
5 |
Press down Start button, but the fixture do not work. | The display value and preset value of test times are the same | Press Count Cleared |
| The E-STOP button is not reset | Release E-STOP button |
| There is foreign object in the machine, the machinery is stuck | Remove the foreign object |
| It is not under auto test mode | Press Start button |
| Connection to motor loosen | Reconnect |
| Not in starting position | Homing |
| 6 | Motor rotates but the manipulator does not rotate | Check whether the motor output shaft connector is loose | Re-connect |
| Check whether the drive belt is broken or too loose | Replace the drive belt |
| 7 | Noise | Swivel speed low or too high | Reset the speed |
| Connection to motor loosen | Reconnect |
