The quality gatekeeper of new-energy charging infrastructure

As the new-energy vehicle market continues to grow, charging stations and charging… gun Wait Core Quality control of components has become a focal point in the industry. Charging connector In practical applications, these components must withstand high voltage, large currents, frequent plugging and unplugging, and harsh environmental conditions. Traditional manual testing methods can no longer meet the stringent requirements of mass production for test efficiency, data traceability, and consistent measurement accuracy. The industry urgently needs a solution that can achieve… Automated testing 、 Multi-standard compatibility and also possesses Data traceability capability A comprehensive testing solution.

In the field of charging equipment testing, ZHONGJIA EQUIPMENT (Abbreviated as “Zhongjia Testing”), by gaining deep insights into industry pain points, has developed an intelligent testing‑equipment portfolio that spans the entire value chain—including functional testing, safety‑regulation compliance testing, durability testing, and performance validation—providing efficient solutions to companies across the new‑energy industry’s upstream and downstream sectors. Precision Quality control tools.

Charging gun Comprehensive Testing: A Breakthrough in Batch Detection Efficiency

For charging gun In the scenario of full‑batch inspection at manufacturing plants, Zhongjia Testing has launched… ZJ-CDQ08 charging gun Integrated Testing System Showcase Significant the technological advantages of the system. The system employs PLC Input/Output Scan Detection The technology can automatically perform basic functional tests—such as open‑circuit, continuity, short‑circuit, and wire‑sequence errors—in a single step, while also measuring the main‑line continuity resistance, CP/CC resistance (Resistance range: 1–5,000 Ω, accuracy: 1%), electronic lock switch functionality, inter‑wire insulation (insulation voltage: DC 100–1,000 V; resistance range: 1 MΩ–1 GΩ; accuracy: ±5%), and dielectric withstand testing (AC 0–5 kV / DC 0–6 kV; accuracy: ±1.5%), among other critical parameters.

The system's Core The value lies in Test data is traceable. Feature — Rechargeable for each unit gun It supports the entry of independent QR codes, automatically saves test results and associates them with barcodes, and provides a communication interface for uploading data to… MES system , enabling data management across the entire product lifecycle. This design effectively addresses the industry’s longstanding challenges of fragmented data and poor traceability in conventional testing. The system is compatible with a wide range of AC/DC charging standards, including Chinese national standards, European standards, U.S. standards, and Tesla’s specifications. gun The standard provides export-oriented enterprises with convenient multi‑standard switching capabilities.

For AC charging gun the demand for rapid testing, AC charging gun Comprehensive Tester ZJ-CDQ01 Insulation, dielectric strength, continuity, resistance, and so on Core The functions are integrated into a unified testing workflow. This device is equipped with… Audio-visual alarm notification The system is equipped with a mechanism that automatically triggers an alarm and displays text prompts when abnormalities such as insulation failure, dielectric breakdown, incorrect polarity, or excessive resistance are detected, thereby preventing defective products from advancing to downstream processes. Its touchscreen interface supports the storage and recall of various test parameters. Significant It has shortened the changeover time on the production line.

 

 

 

 

Temperature Rise Test: Eliminating the Impact of Current Fluctuations on Test Accuracy

The charging connector under load current Temperature Rise Performance This directly affects operational safety. In conventional temperature-rise tests, factors such as power‑supply voltage fluctuations, variations in the resistance of connecting leads, and changes in the test specimen’s resistance often lead to unstable test currents, thereby compromising the accuracy of the temperature measurements.

ZJ-WS500A Temperature Rise Test System Through Constant Current Source Technology By addressing this key pain point, the system delivers a stable, adjustable DC current ranging from 0 to 500.0 A while effectively mitigating external interference. It supports 30 programmable current‑time profiles, enabling flexible customization of multi‑step current‑time combinations to meet complex requirements. Thermal cycling test Requirements: The equipped 16-channel temperature measurement points (including ambient temperature) deliver measurement accuracy of ±1% of reading plus 1°C within the range of 0 to 200°C. Temperature data are automatically recorded by the computer, and temperature–time curves are generated for convenient real-time querying and analysis.

Notably, the system also integrates Smoke detection and alarm Functionality—when the product emits smoke, the system triggers an alarm and shuts off the current output, significantly enhancing safety during testing. The system also features a voltage-drop measurement function (0–500 mV, resolution 0.1 mV, accuracy 1%), enabling… Comprehensive Assess charging gun Electrical performance.

For those requiring testing in high-temperature environments New energy wiring harness For such products, the **ZJ-WS1500A Temperature Rise Test System (including a high‑temperature chamber)** offers an integrated solution. The system features built-in high‑temperature heating, with a temperature control range from ambient up to 100°C and a temperature accuracy of ±2°C, meeting the requirements of temperature rise testing under specific operating conditions. Its high‑current output capability—adjustable from DC 10 to 1500.0 A—combined with voltage drop measurement (0–1000 mV) and resistance measurement (0–200 mΩ), enables… Comprehensive Evaluate the performance of high-power products. If the thermocouple wire is equipped with a push‑in connector design, then… Significant It has improved operational convenience and maintenance efficiency.

 

 

 

 

 

Lifetime Testing: Validation Capability Simulating Real-World Usage Scenarios

Charging gun When used outdoors, connectors are subjected to repeated mating and unmating while immersed in corrosive liquids, a complex operating condition that is difficult to accurately replicate in conventional test environments. Charging gun The plug‑and‑socket endurance tester (with solution) features an innovative multi‑solution automatic immersion system. Function: automatically charges gun The product is sequentially immersed in three solutions—rainwater, saltwater, and turbid water—and then subjected to immersion–retraction–power‑on cycles, accurately simulating its outdoor service life.

This device employs Servo electric cylinder , servo module and pneumatic cylinder combination drive; the insertion/extraction speed can be set arbitrarily within the range of 0.1 to 0.80 m/s, meeting the test requirement of 0.8 ± 0.2 m/s specified in GB/T 20234.1-2023. The insertion/extraction force measurement can reach Maximum 500 N, a high-precision digital pressure module paired with computer-based curve display, enables real-time monitoring of insertion/extraction force trends. The system adheres to the principle of “ensure continuity when required, ensure disconnection when required,” and automatically triggers an audible and visual alarm and shuts down upon sample failure, thereby preventing equipment damage and data distortion.

Targeting Electrical insertion and extraction force the need for precise measurement, Charging gun Insertion/Removal Life Testing Machine ZJ-CBSM01C Provided multiple gun Head‑compatible charging solution, supporting Chinese, European, U.S., and Tesla AC charging standards. gun Specifications: Equipped with four contour‑matching fixtures for quick interchangeability. The device achieves a plug‑and‑socket force measurement accuracy of 0.01 N resolution and 1% precision, and allows users to set an upper force limit for automatic shutdown and alarm. Its… Life expectancy statistics feature Supports over 15,000 cyclic tests, with customizable insertion/removal cycles; enables data storage and binding via QR code or barcode scanning; automatically generates Excel reports; and supports integration with… MES/ERP system Communication enables closed-loop management of production data.

 

 

 

 

Charging Station Testing: Comprehensive Coverage from Protocol Verification to Aging Tests

The testing of DC charging piles has long relied on real-vehicle validation, which is inconvenient and does not… Comprehensive , drawbacks such as the inability to simulate real-world faults and the significant time and effort required. EVD1000V-30kW×2 DC Charging Pile Test System Through built-in load+ National/European Standard BMS Simulation System , it can realistically simulate the charging process and various fault scenarios, thereby circumventing many of the limitations inherent in real-vehicle testing.

The device is equipped with Comprehensive of the Fault simulation capability : Multi‑range DC+ and DC‑ leakage resistance simulation (14 ranges), R4 resistor setting (5 ranges), and simulations of battery positive connection, reverse connection, and no connection, helping R&D engineers quickly pinpoint issues. Its Communication Conformance Testing With tools such as functional‑compatibility analysis report generation, real-time message translation, and Gantt‑chart waveform output for messages, fault analysis becomes more intuitive and efficient. The system supports automatic SOC incrementation and allows users to set the charging duration, enabling automated aging tests. Significant Reduce labor costs.

For scenarios that require on-site testing and maintenance, VCD-BG01 Portable DC Charging Pile Tester It features a trolley‑case‑style design for easy portability. The device complies with the national standard GB/T 27930‑2015 communication protocol and is also compatible with GB/T 27930‑2011. Its 7‑inch touchscreen interface, paired with host‑computer software, enables functions such as message waveform visualization, CAN‑box transmission and reception, Chinese‑language message decoding, real‑time saving of CAN message data, and message statistics. Comprehensive of the CAN Message Analysis Functionality suitable for the daily inspection and maintenance of charging stations.

 

 

 

 

 

 

 

In the aging‑test phase for charging stations, conventional resistive loads suffer from high energy consumption, significant heat generation, and elevated ambient temperatures. Zhongjia Testing’s… AC Three-Phase Charging Pile Aging Test Bench ZJ-LH820C Adopt Energy-feeding load The technology enables energy recovery, returning electrical energy to the grid without pollution, thereby conserving energy while preventing ambient temperature rise. Each system module is equipped with 20 test stations, allowing simultaneous online testing of multiple products. The software automatically monitors the aging process; in the event of a fault or defective unit, it promptly disconnects power and triggers an alarm, while automatically short-circuiting the faulty sample so that other stations can continue testing. Test data is automatically linked to the product barcode and stored, enabling the generation of electronic reports and integration with… MES system Integration to meet the data management needs of intelligent manufacturing.

 

 

 

 

Liquid Cooling Technology and Hermeticity Testing: Addressing New Challenges in High-Power Charging

As charging power continues to increase, Liquid-cooled charging gun It has become a technological pathway for addressing thermal management challenges. ZJ-YLQ01 Liquid Cooling gun Test bench Specialized testing capabilities are provided for the flow rate, pressure, and temperature performance of liquid‑cooling tubes. This equipment can separately measure the tube’s flow rate (0–10 L/min), pressure (0–2 MPa, with an accuracy of ±10 kPa), and temperature (−20°C to 120°C, with an accuracy of ±0.5% of full scale), while the medium temperature is controllable within the range of 15°C to 60°C.

The computer can generate flow, pressure, and temperature curves and display data in real time. The alarm thresholds for pressure and temperature are user‑configurable, ensuring the test process remains safe and under control. The device is equipped at its base with… All-purpose Steering wheels, with inlet and outlet hoses that can be extended by more than 2 meters, Significant It has enhanced the convenience of on-site operations. Core The components include a fan, a heat sink, a compressor, a plate heat exchanger, a water pump, a PTC heater, an electric water valve, and more, forming a complete liquid‑cooling circulation test system.

For products such as charging connectors and batteries, Air-tightness testing For your needs, Zhongjia Testing’s airtightness testers employ either direct‑pressure or differential‑pressure measurement principles, using air as the test medium and incurring no operating costs. The differential‑pressure testing method effectively compensates for pressure fluctuations caused by temperature variations and deformation of the test specimen, ensuring precise detection of even the smallest leaks. The sensors offer 24‑bit resolution, with a display accuracy of 0.1 Pa, and a standard test pressure range of 0–100 kPa (with optional ranges available). The instruments support switching among six pressure units and seven leak‑rate units, and provide CSV‑format data export as well as Modbus RTU communication.

 

 

 

 

 

Safety Testing: Building Multi-Layered Protection for Electrical Safety

In the field of safety compliance testing, Zhongjia Testing has developed solutions tailored to the specific needs of the new energy charging industry. A/B Type Residual Current Operated Circuit Breaker Tester This device supports testing of various current waveforms, including Type B (DC superimposed, two-phase/three-phase rectification, smoothed DC, high-frequency sine waves, and composite waves), Type A (pulsating DC at 0°, 90°, and 135°), and AC type (mains-frequency sine waves), thereby meeting the requirements of multiple standards such as IEC 62423/GB 22794, IEC 62752/NBT 42077, and GB 16916.1.

The equipment adopts DSP28335 chip , FPDA, AD9954 digital frequency module, etc. Core The device achieves an AC‑type 50 Hz residual current output ranging from 2 mA to 7 A with an accuracy class of 0.3, while the A‑type half‑wave pulsating residual current is accurate to class 2.0, and the smooth DC current is accurate to class 0.5. The microcontroller‑based control system can automatically perform product testing according to the selected test procedure and includes a fault‑indication function. Significant It has improved the efficiency of batch testing.

For charging gun Pile aging test, AC charging gun Pile Aging Test Cabinet Provided Intelligent CP signal judgment The function automatically measures the CP signal’s frequency, voltage, and duty cycle (converted into protocol current); if any parameter fails to meet the specifications, an audible alarm sounds and the display flashes. The system can also detect… CC signal It also displays the cable’s rated current; if there is a mismatch or an incorrect resistance value, an alarm will be triggered. This device supports Type 2 and Type 3 charging according to Chinese, European, and U.S. standards. gun The unit can be configured with a 24-hour aging test duration, and its load power range covers products up to 7 kW in single-phase and up to 22 kW in three-phase.

 

 

 

 

Mechanical Performance Verification: From Insertion/Removal Force to Bending Life All-round Assessment

The mechanical performance of charging connectors directly affects user experience and service life. ZJ-1220S Fully Automatic Insertion/Extraction Force Testing Machine Equipped with Patent Automatic centripetal device , ensuring automatic alignment of male and female connectors, preventing unilateral loading and yielding accurate insertion/extraction force data. Equipped with a servo motor and a high-rigidity structural design, this device maintains precision even under prolonged use and can be optionally configured with… Dynamic Impedance Testing System While testing the insertion/extraction force, also measure the dynamic impedance and plot the resulting curve.

The test items cover multiple dimensions, including single‑hole connector insertion/extraction, insertion/extraction life, normal force, full‑row insertion/extraction, single‑pin and plastic retention force, as well as compressive/tensile failure strength. Measurement… Maximum Load: 50 kg, most Small load capacity: 0.01 kg; testing speed range: 0–150 mm/min; X/Y-axis travel range: 0–70 mm. The computer interface supports both drop-down menu selection and direct data entry, and allows storage and printing of load–displacement curves, load‑decay life curves, and inspection reports.

Regarding charging gun of the cable Bending life Assessment, Charging gun Bending Life Testing Machine It offers load‑testing capabilities, with a reserved load‑connection port rated for currents of ≥800 A, enabling bent‑under‑load tests that more accurately simulate real‑world usage conditions. When the test specimen is bent to the point where electrical current can no longer pass, the instrument automatically stops and records the number of cycles, facilitating reliable life‑cycle assessment. This equipment complies with the test requirements specified in GB/T 20234.1‑2023 Section 6.2.10.4, GB/T 11918.1‑2014 Chapter 24.4, and IEC 62196‑1:2022 Chapter 26.4. Bend angle, bending speed (0–80 cycles/min), and test cycle count (0–9,999,999) are all programmable; the weight of the applied counterbalance can be configured between 20 N and 180 N, and it accommodates test cables with diameters ranging from 5 mm to 70 mm.

 

 

 

 

Industry Application Value: End-to-End Support from R&D to the Production Line

Zhongjia Testing’s product portfolio has been established, ranging from… Research and Development Verification to Production line inspection Then again After-sales maintenance Its end-to-end coverage capability. During the R&D phase, EVD1000V-30kW×2 DC Charging Pile Test System Its communication compliance testing and fault‑simulation capabilities help engineers quickly identify protocol‑compatibility issues; during the production‑line inspection phase, ZJ-CDQ08 charging gun Integrated Testing System its batch testing capability and data traceability function, Significant It has enhanced the level of quality control at the factory; in the after-sales maintenance phase, VCD-BG01 Portable DC Charging Pile Tester Its portability and packet-analysis capabilities provide a professional tool for on-site fault diagnosis.

This end-to-end testing solution is helping charging‑equipment manufacturers address the compatibility challenges posed by multiple standards—including Chinese, European, U.S., and Tesla—while meeting quality‑control requirements across various dimensions, such as functional testing, safety compliance testing, durability testing, and performance validation. Through… Automated testing 、 Data Traceability 、 MES system integration Through technological means, we are driving the transformation of charging equipment manufacturing toward intelligence and digitalization.

Technology Evolution Direction: Integration of Energy Efficiency, Environmental Protection, and Intelligentization

In the technological evolution of testing equipment, Zhongjia Testing has demonstrated a commitment to… Energy conservation and environmental protection Forward-looking thinking. AC Three-Phase Charging Pile Aging Test Bench ZJ-LH820C The energy‑regenerative load technology employed enables the recovery and return of electrical energy to the grid, achieving energy savings of over 80% while eliminating the substantial heat generated by conventional resistive loads that would otherwise raise ambient temperatures. This technological approach not only reduces operating costs for enterprises but also aligns with the green manufacturing trend under the “dual carbon” goals.

In terms of intelligence, Data-Driven Quality Management The philosophy has been integrated throughout the entire product design process. From… ZJ-CDQ08 charging gun Integrated Testing System QR code traceability, to Charging gun Insertion/Removal Life Testing Machine ZJ-CBSM01C the integration with MES/ERP systems, and further to ZJ-WS500A Temperature Rise Test System Curve generation and data analysis have established a closed-loop system for data acquisition, storage, analysis, and application, providing robust data support for quality control throughout the product’s entire lifecycle.

Summary

The charging-pile testing equipment market is currently at a critical stage of technological upgrading. ZHONGJIA EQUIPMENT By gaining deep insights into industry pain points, we have developed a comprehensive coverage of… Comprehensive Testing of Charging Connectors 、 Temperature Rise and Thermal Cycling Test 、 Lifetime and Mechanical Performance Testing 、 Charging Pile and Charging System Testing 、 Air-tightness and Liquid Cooling Performance Testing 、 Safety and Electrical Performance Testing A comprehensive solution spanning six major product lines. Drawing on years of technological expertise in automation, multi-standard compatibility, data traceability, and energy efficiency and environmental protection, its products provide a reliable foundation for enhancing the quality of new‑energy charging infrastructure.

As charging power continues to increase, liquid-cooling technology becomes more widespread, and the development of smart charging networks accelerates, the technical requirements for testing equipment are also steadily rising. Equipped with… End-to-end testing capability 、 Data-Driven Management 、 Energy-saving and environmentally friendly features Its intelligent testing solutions will serve as a critical enabler for charging equipment manufacturers to enhance their market competitiveness.