I. Technical Challenges and Standardization Needs in the Field of Charging Equipment Testing

With the rapid growth of the electric vehicle industry, the quality and safety of charging infrastructure have become key areas of focus. As a critical component that connects vehicles to the power grid, the “charging gun” directly impacts users’ charging experience and system safety through its functional reliability, safety performance, and compliance with relevant standards. Currently, the industry faces significant technical challenges, including complex requirements for multi‑standard compatibility validation, electrical safety testing, verification of temperature‑protection features, and assessment of product lifespan.

ZHONGJIA EQUIPMENT, a high-tech enterprise specializing in the R&D and manufacturing of testing equipment, has, based on years of technical expertise and engineering experience, actively participated in the standardization process of charging equipment testing technologies. Through continuous technological innovation and product iteration, the company has provided numerous testing solutions to the industry and has obtained SGS‑recognized supplier certification.

II. Interpretation of Multi-Standard Charging Gun Testing Technology

The key to “charging gun” testing technology lies in achieving multi‑standard compatibility verification. According to technical documentation from Zhongjia Testing, the ZJ‑CDQ08 “Charging Gun Comprehensive Test System” can perform functional tests for a variety of charging‑gun standards, including Chinese national standards, European standards, U.S. standards, and Tesla’s proprietary standard. The underlying technical principle of this multi‑standard compatibility testing is based on standardized electrical parameter measurement and communication protocol validation.

Standardization of Electrical Performance Testing

The electrical performance testing of “AC charging guns” primarily covers functional parameters such as insulation, dielectric strength, continuity, and resistance. The technical implementation of the ZJ‑CDQ01 “AC Charging Gun Comprehensive Tester” demonstrates that, for both “three‑phase AC charging guns” (L1, L2, L3, N, E) and “single‑phase charging guns” (L, N, E), a comprehensive electrical safety assessment system must be established. This testing approach ensures that the electrical safety performance of the charging gun meets the relevant standard requirements under various operating conditions.

Temperature Protection Function Verification Technology

Temperature protection is a critical technical component of charging safety. The vehicle‑interface temperature‑protection test rig (ZJ‑JR04), developed by Zhongjia Testing, employs PDI temperature controllers for automated temperature regulation, accurately replicating the heating conditions of the charging gun’s contact pins and enabling testing of the temperature‑sensing and protective functions of the charging gun head. This technology complies with the requirements of Clause 9.4.2.2 in GB/T 44263‑2024 for DC vehicle‑interface temperature‑protection testing, providing the industry with a standardized validation protocol for temperature protection.

III. Insights into Technological Development Trends in the Charging Equipment Testing Industry

In-depth application of automated testing technologies

Industry trends indicate that automated testing technologies are emerging as a key enabler for enhancing both efficiency and accuracy in inspection processes. An analysis of Zhongjia Testing’s product‑specific technical features reveals that the integration of PLC‑based control systems with touch‑screen interfaces has become a standard configuration for testing equipment. This control approach not only automates the testing workflow but also supports data traceability and robust quality‑management capabilities.

Data-Driven Quality Management System

Modern charging‑equipment testing is evolving toward a data‑driven quality‑management approach. By leveraging QR‑code scanning and automated data‑logging capabilities, testing equipment has established a comprehensive quality‑traceability system that covers the entire product lifecycle. This data‑centric management model provides manufacturers with sophisticated tools for quality control, helping to enhance product consistency and reliability.

Assessment of Insertion/Removal Life and Mechanical Reliability

The technology for assessing the mechanical life of charging guns is becoming increasingly important. The ZJ-CBIXZ charging gun insertion–extraction life‑testing machine, controlled by an original Japanese programmable logic controller (PLC), enables automated testing of the mechanical durability of charging gun charging stations. This testing approach provides technical support for evaluating the long-term reliability of charging equipment.

IV. Integrated Development of Technical Standardization and Industry Practice

Localization of International Standards

The development of charging‑equipment testing technologies requires striking a balance between international standards and local applications. As demonstrated by Zhongjia Testing’s technical experience, testing equipment must simultaneously comply with multiple standards, including GB/T, IEC, and JIS, which in turn demands that testing technologies possess robust standard‑adaptability and flexibility.

Systematic integration of detection technologies

The shift from single‑function testing to comprehensive performance evaluation has become a defining trend in the industry. The ZJ‑ZH8163 “AC Single‑ and Three‑Phase Charging Gun and Pile Comprehensive Test System” exemplifies this trend toward technological integration, enabling multiple testing functions with a single unit and thereby enhancing testing efficiency and equipment utilization.

V. Industry-Oriented Technical Recommendations and Development Directions

Based on the current state of technological development and an analysis of market demand, it is recommended that charging‑equipment manufacturers focus on the following key areas in product development and quality management:

Establish a comprehensive multi‑standard compatibility verification system to ensure that products can meet the diverse requirements of different markets and application scenarios; strengthen the design validation of thermal protection and electrical safety features to enhance product reliability under extreme operating conditions; advance the automation and data‑driven management of testing processes, and build a data‑centric quality control framework; place particular emphasis on assessing product mechanical life and long‑term reliability, and use rigorous testing methodologies to validate the soundness of product designs.

The advancement of charging‑equipment testing technologies requires coordinated collaboration across all segments of the industry chain. By adopting standardized testing methods and technical specifications, the sector can be propelled toward higher quality and enhanced safety.

VI. ZJ-WS1000A Temperature Rise Test System: Multi‑dimensional temperature rise testing to fortify the safety barrier.

The ZJ-WS1000A temperature-rise testing system is specifically designed for thermal‑rise verification of critical components such as charging guns, charging stations, cable harnesses, and terminal blocks, addressing the pain points of conventional temperature‑measurement methods with its hallmarks of precision, comprehensiveness, and efficiency.

• All-Scenario Temperature Measurement Supports synchronous connection of 16 temperature sensors, enabling simultaneous monitoring of temperature changes at the charging gun connector, cable, terminals, and internal modules of the charging station. The measurement range spans from –40°C to 500°C, with an accuracy of ±0.5°C, ensuring no temperature‑measurement blind spots.

• Real-time Intelligent Early Warning The system collects temperature data in real time and generates dynamic curves. When the temperature at a particular measurement point approaches the standard threshold—such as the 70 K temperature rise limit specified by national standards—the system immediately triggers an audible and visual alarm, enabling inspection personnel to quickly pinpoint the issue and preventing non‑conforming products from advancing to the next process step.

• Process Efficiency Improvement : This enables seamless integration with the aging test phase, allowing temperature rise testing to be conducted concurrently during the later stages of the aging test. Compression The total testing time per unit has been reduced, resulting in a 50% increase in testing efficiency.

VII. ZJ-LH820C AC Single-Three-Phase Charging Pile Aging Test Bench: Energy-Regenerative Aging Testing, Addressing High-Power Consumption Challenges

As a highly efficient aging‑test device, the ZJ‑LH820C’s standout advantage lies in its built-in regenerative load technology: it recycles and reuses the output energy from the charging station under test, purifying it to eliminate any contaminants before feeding it back into the utility grid, thereby achieving closed‑loop energy utilization. This technology directly addresses the energy consumption and heat‑generation challenges of conventional equipment:

• Environmental protection Energy conservation : The energy recovery rate exceeds 85%, reducing the average daily power consumption of a single production line from 3,000 kWh to below 450 kWh, resulting in monthly electricity cost savings of over RMB 50,000 and completely eliminating the burden of high energy consumption.

• Temperature control and consumption reduction : Since energy is no longer dissipated as waste heat, the workshop’s ambient temperature has dropped by 6°C compared to before, reducing air-conditioning cooling costs by 70% while also preventing high temperatures from compromising the accuracy of testing equipment.

• Highly efficient adaptation : Supports full‑power‑range testing of AC single‑phase and three‑phase charging piles, featuring a zoned control architecture that enables simultaneous operation. 20 Taiwan Charging station aging tests, coupled with automated data logging capabilities, Shorten Single-unit equipment aging test duration, efficiency improved 99%。