AC Charging Gun Comprehensive Test System EV Connector Testing
Machine This test system is mainly used for functional inspection of AC
plugs according to Chinese (GB), European (EU), and American (UL)
standards. Each plug can be assigned a unique QR code, and the test
results are automatically saved in reports. Qualified results can
be printed directly. All functions are tested automatically in a
single run, providing high efficiency and labor savings, making it
suitable for mass production full inspection in factories. Testing Functions - Breakage, continuity, short circuit, and wiring sequence tests for
each individual wire
- Continuity resistance test of the main conductor
- Built-in resistance measurement (including both pressed and
unpressed states of push-button switches)
- Current carrying capacity verification and voltage drop measurement
- Insulation test between wires
- Dielectric withstand (high-voltage) test between wires
- Thermocouple wire testing
Technical Specifications | Power Supply | Single-phase AC 220V / 50Hz |
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| Air Supply | 0.6 MPa |
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| Control System | PLC + Industrial PC |
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| Barcode Scanning | The device comes with a scanner to read barcodes or QR codes on the
test samples. Scan the product before testing; after the test, the
scanned code is automatically associated with the test record,
enabling traceability. |
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| Wire Continuity Tests | Break, continuity, short circuit, and wiring sequence tests are
performed via PLC Input/Output scanning. PLC automatically
determines pass/fail. |
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| Built-in Resistance Range | 1–5000 Ω, Accuracy: 1%
Upper and lower limits can be set to determine product quality. |
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| CC & PE Resistance (Button Pressed / Not Pressed) | 16A AC plug: Not Pressed RC: 680Ω,Pressed RC+R4:3.38 kΩ
32A AC plug:Not Pressed RC: 220Ω,Pressed RC+R4:3.52 kΩ
63A AC plug:Not Pressed RC: 100Ω,Pressed RC+R4:3.4 kΩ
The measurement accuracy of the resistance must reach 1%–2%. |
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| Thermistor Testing Range | 100–50,000 Ω, Accuracy: 2%
Upper and lower limits can be set to determine continuity quality. |
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| Current Carrying Capacity & Voltage Drop Test | Measures voltage drop across connectors under rated and overload
current conditions.
Built-in three-phase adjustable transformer: 0-380V output,
adjustable three-phase load 0-35A.
Supported test ranges:
3.3 kW 16A single-phase
7.4 kW 32A single-phase
11 kW 16A three-phase
22 kW 32A three-phase |
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| Insulation Resistance Test | Single-phase: L-N, L-E, E-N
Three-phase:L1/L2/L3/E-N, L1/L2/L3/N-E, N/L2/L3/E-L1, L1/N/L3/E-L2,
L1/L2/N/E-L3
Parameters:Test voltage: DC 100–1000V (adjustable) Lower limit: 1 M–1 GΩ (adjustable) Accuracy: ±5% Alarm when resistance < set value |
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| Dielectric Withstand (Hi-Pot) Test | Single-phase: L-N, L-E, E-N
Three-phase: L1/L2/L3/E-N, L1/L2/L3/N-E, N/L2/L3/E-L1,
L1/N/L3/E-L2, L1/L2/N/E-L3
Parameters:Test voltage: AC 0–5 kV / DC 0–6 kV (adjustable) Leakage current limit: AC 0.1–20 mA, DC 0.01–5 mA Accuracy: ±1.5% + 3 digits Digital display of voltage, automatic programmable adjustment Alarm if leakage current exceeds set value |
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| Test Station | Single station, one product per test |
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| Plug Holders | EU AC vehicle plug holder, EU AC pedestal plug holder, GB AC plug
holder, US AC plug holder |
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| Tail Plate | Special pressing fixture matching the test product, with clamp and
protective plate |
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| Socket Height | 750–1000 mm, ergonomically designed |
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System Overview |
