EV Charging Connector Comprehensive Testing System For AC Type 2 And DC CCS2

This testing system is specifically developed for comprehensive performance verification of AC Type 2 and DC CCS2 charging connector cable assemblies. It enables fast, accurate, and fully automated inspection of finished charging connectors to ensure product quality and compliance with manufacturing requirements.

The system integrates multiple testing functions into a single automated sequence, allowing all required inspections to be completed in one operation. This significantly increases testing efficiency, reduces manual intervention, and minimizes the risk of human error.

Designed for high-volume production environments, the system is an ideal solution for 100% end-of-line inspection, helping manufacturers improve product consistency, production throughput, and quality control management.

• Open circuit, continuity, short circuit, and wire sequence misalignment test for each wire
• Main conductor continuity resistance test
• Built-in resistor test (including both button pressed and button released conditions)
• Insulation test between conductors
• Withstand voltage test between conductors
• Thermocouple wire test

• Power Supply: Single-phase AC 220V, 50Hz
• Pneumatic Supply: 0.6 MPa compressed air

Integrated PLC and Industrial PC control system for stable and reliable operation. Supports seamless communication with MES (Manufacturing Execution System) for production data management and traceability.

• Equipped with a dedicated barcode scanner for product identification
• Supports scanning of barcodes or QR codes before testing
• Test results are automatically linked to the corresponding product code, enabling complete traceability and historical data retrieval

• Integrated compact label printer for automatic generation of test labels
• Labels can include serial number, electrical rating, test date and time, operator information, and test status
• Labels are printed only for products that pass all inspection requirements

• Open-circuit detection
• Continuity verification
• Short-circuit detection
• Wiring sequence verification

These inspections are automatically executed through PLC-controlled inputs and outputs. Upon completion of the testing cycle, the system instantly evaluates and determines the pass/fail status of the product.

Supports continuity resistance testing for: L1, L2, L3, N, PE, CP

• Measurement Range: 1 Ω to 5000 Ω
• Measurement Accuracy: ±1%
• Upper and lower limits can be set to determine whether the resistance value is qualified

• Fully automated testing process
• Reliable pass/fail judgment
• Comprehensive product traceability
• MES integration capability
• Reduced operator involvement
• Improved production efficiency and quality control
• Ideal for high-volume manufacturing and 100% end-of-line inspection

• L-N
• L-E
• E-N

• 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

• Positive-Negative
• Positive-Ground
• Negative-Ground

• Insulation voltage: DC100~1000V adjustable
• Lower limit setting: 1M~1GΩ adjustable
• Accuracy: ±5%
• Alarm insulation resistance can be set: when the resistance value is lower than the set value, it is judged as NG

• L-N
• L-E
• E-N

• 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

• Positive-Negative
• Positive-Ground
• Negative-Ground

• Withstand voltage: AC 0~5kV / DC 0~6kV adjustable
• Upper limit of leakage current: AC: 0.1mA~20mA adjustable, DC: 0.01mA~5mA adjustable
• Accuracy: ±1.5% + 3 digits
• Display mode: Digital meter displays the current voltage
• Voltage adjustment mode: Automatic programmable control
• Alarm detection: When the leakage current value exceeds the set value, it is judged as NG

ONE test station (Customizable)

• Range: 0~500N
• Resolution: 0.1N
• Accuracy: 1%
• Automatically saved into reports

The system is equipped with professional testing software compatible with Win-7 and Win-10 operating systems. All testing parameters, inspection configurations, and system settings can be conveniently managed through an intuitive software interface, simplifying operation and reducing setup time.

During the testing process, inspection results are automatically collected and stored in real time. Each product's test record is securely saved to the local database, ensuring complete traceability and reliable quality documentation.

Operators can quickly search, review, and analyze historical test records through the software platform. The centralized data management system enables efficient retrieval of product information and testing history whenever required.

The testing system is designed with reserved communication interfaces for seamless integration with Manufacturing Execution Systems (MES). Test results can be automatically uploaded to the customer's MES database, supporting production monitoring, quality management, process control, and traceability requirements.

Test records can be exported in multiple formats, including:

• Excel (.xlsx)
• Text Files (.txt)

The exported data can be used for quality analysis, production reporting, statistical evaluation, and long-term record keeping.

• PC operation with intuitive user interface
• Real-time test data recording and storage
• Fast search and retrieval of historical records
• Supports MES connectivity and automated data transfer
• Flexible data export for analysis and reporting
• Enhanced production traceability and quality control
• Suitable for smart manufacturing and Industry 4.0 environments