EV Plug & Connector Drive-Over Test Equipment IEC 62196-1 EV
Charger Durability Testing
Overview:
The Vehicle Drive-Over Testing Apparatus is specifically designed
to assess the resistance of EV plugs and connectors against
accidental vehicle crushing. This ensures that charging accessories
meet IEC 62196-1:2022 requirements for durability and safety,
providing manufacturers with reliable test data to validate product
compliance.
The system realistically simulates the situation where a charging
connector is left on the ground and driven over by a vehicle tire.
By applying a controlled force and speed, it evaluates whether the
accessory can withstand damage without compromising safety or
functionality.
Purpose and function:
Safety and durability testing: The main purpose is to ensure that
EV charging plugs and connectors can withstand damage if a vehicle
drives over them. This is a crucial safety test required by
international standards like IEC 62196-1.
Realistic simulation: The apparatus is designed to accurately
simulate the forces and motion of a real automobile tire rolling
over the component. This often involves a reciprocating rolling
motion to replicate both forward and backward movements.
Standard compliance: Manufacturers use this equipment to test that
their products comply with the specific requirements and parameters
of automotive and electrical safety standards.
Key components and features:
Test tire and rim: The apparatus uses a standard automotive tire
(e.g., P225/75R15) mounted on a steel rim. The tire's pressure is
set to a specific standard value.
Crushing force mechanism: The system applies a specific crushing
force to the component, typically 5000 N for cars and 11000 N for
larger vehicles. A precision force sensor and adjustable weights
ensure the accuracy of the applied force.
Motor and drive system: A servo motor combined with heavy-duty
rails and rollers drives the test tire to simulate the vehicle's
motion. This allows for precise control of the speed and direction
of the roll-over.
Component fixture: The apparatus includes a jig or sliding device
to securely hold the component being tested. This prevents it from
moving significantly during the test while allowing it to be
oriented in different positions to simulate how it might land.
Concrete test floor: The test item is placed on a concrete or
cement-like surface, replicating the environment of a real-world
parking area or garage.
Control system: A Programmable Logic Controller (PLC) with a
human-machine interface (touch screen) allows operators to control
and monitor the test parameters, such as speed and force.
Technical Parameters:
| Item | Specification |
|---|
| Test Station | Single station |
| Control Method | PLC integrated control with 7-inch color touchscreen |
| Operation Modes | Manual or program-controlled |
| Drive System | Motor + worm gear system |
| Drive-Over Stroke | 0 – 2.0 m |
| Crushing Force | 5000 ± 250 N or 11000 ± 550 N (adjustable) |
| Drive-Over Speed | (8 ± 2) km/h, adjustable |
| Rolling Method | Linear motor drive, forward & reverse reciprocating rolling |
| Tire Specification | 1× P225/75R15 tire + rim (for 5000 N), 1× heavy-load tire + rim
(for 11000 N) |
| Tire Pressure | (220 ± 10) kPa |
| Base Plate | Simulated cement/concrete floor with fixing clamps |
| Load Adjustment | Counterweight system, adjustable by cantilever crane |
| Display & Timing | Touchscreen parameter setting and test cycle display |
| Deceleration System | Built-in braking mechanism to prevent rigid collisions |
| Safety Protection | Protective fence, anti-deflection design, shock-absorbing base with
wheels |
Compliance
IEC 62196-1:2022 Clause 33
IEC 62752:2016 Clause 9.34
Applications
EV plug and connector testing
Charging station accessory mechanical endurance verification
Laboratory compliance testing for international certification
