IEC 62196-1 EV Charging Plug And Socket Withdrawal Insertion Force Test Equipment for Connectors
The EV Charging Plug Insertion & Withdrawal Force Tester is a specialized mechanical testing system designed to evaluate the insertion force and withdrawal force of electric vehicle charging plugs, sockets and vehicle connector interfaces.
Developed for testing requirements associated with IEC 62196-1, the system provides a controlled and repeatable method for measuring the force required to mate and disconnect EV charging interfaces.
Unlike conventional manual force gauges, this tester combines a servo motor drive, PLC intelligent control system, precision force sensor and digital displacement measurement to provide accurate control of the testing process.
The equipment is suitable for EV connector manufacturers, charging equipment manufacturers, automotive laboratories, certification organizations, R&D departments and quality control laboratories.
Key Features
Servo Motor Controlled Force Testing
The tester uses a servo motor drive system to generate controlled linear movement during insertion and withdrawal testing.
The servo system allows the operator to establish a stable and repeatable test speed while the force sensor continuously monitors the applied load.
This provides a more consistent testing process than manual force measurement.
High-Precision Force Measurement
A precision force sensor is integrated into the testing mechanism to monitor the actual force applied to the EV charging interface.
- Force Range: 10-1000 N
- Loading Accuracy: ±0.5%
- Minimum Force Display: 0.01 N
This high-resolution measurement capability allows laboratories to identify relatively small changes in insertion or withdrawal force.
Digital Displacement Measurement
The equipment provides a minimum displacement display resolution of: 0.01 mm
This enables users to monitor the movement of the charging plug or connector during the test and establish a more controlled relationship between force and displacement.
PLC + Touchscreen Control
The complete test sequence is controlled through an intelligent PLC control system with color touchscreen HMI.
Operators can set and monitor test parameters directly through the interface. The system can be configured for:
- Test force
- Test speed
- Test position
- Test cycle
- Force limit
- Test status
- Automatic stop conditions
This makes the equipment suitable for both laboratory research and production quality control.
Technical Specifications
| Test station |
Single station |
| Electrical control method |
PLC intelligent integrated control, color man-machine touch interface operation |
| Drive mode |
Servo motor drive |
| Test force value |
10~1000N, other ranges can be customized |
| Load accuracy |
±0.5% |
| Minimum load display |
0.01N |
| Displacement minimum display |
0.01mm |
| Insertion direction |
Vertical |
| Test speed |
0.01~100mm/min, adjustable |
| Test cycle |
1-9999 times, adjustable |
| Test floor |
Thickened load-bearing steel plate |
| Lifting device |
Precision slide |
| Specimen Holder |
One special fixture for charging gun interface, the other end is equipped with a CCS2 inlet connector (with front cover) |
| Date Export |
Supports USB data export |
| Protect |
Over-strength alarm, leakage protection |
| Power supply |
AC220V±10%/50Hz, power 1KW |
| Equipment dimension & weight |
About W500*D850*H1550mm, weight: about 120kg |
EV Charging Connector Testing Applications
The equipment can be used for a variety of EV charging interface testing applications.
- EV Charging Plugs: Measure the force required to insert and remove charging plugs from compatible sockets.
- EV Charging Sockets: Evaluate the mating performance of charging socket assemblies.
- Vehicle Connectors: Test mechanical insertion and withdrawal characteristics of EV connector interfaces.
- Charging Gun Assemblies: Evaluate the mechanical performance of charging gun interfaces during mating and separation.
- Locking Mechanisms: The equipment can also be integrated into test programs involving the mechanical interaction between charging plugs, sockets and locking devices, depending on the applicable test configuration. Related Sinuotek equipment covers EV plug/socket insertion, withdrawal and locking-device testing.
