With the rapid growth of the new‑energy vehicle industry, the charging gun—key equipment that connects vehicles to charging infrastructure—directly impacts charging safety and user experience. For manufacturers, selecting appropriate testing equipment to ensure their products meet international standards in terms of functionality, safety, and durability has become a critical challenge in enhancing market competitiveness.

I. Charging gun testing Core Requirements Analysis

Charging gun testing encompasses multiple dimensions, including functional verification, safety compliance validation, durability testing, and performance evaluation. When selecting test equipment, companies should prioritize the following key considerations:

II. Technical Features of the Charging Gun Comprehensive Test System

To meet the batch full-inspection requirements of charging gun manufacturing plants, ZHONGJIA EQUIPMENT has launched the ZJ-CDQ08 comprehensive charging gun test system, offering an efficient, automated solution. The system employs PLC input/output scanning technology to automatically detect issues such as open circuits, continuity, short circuits, and incorrect wire sequencing, while high-precision sensors perform CP and CC resistance tests with a measurement range of 1–5,000 Ω and an accuracy of 1%.

In electronic lock functional testing, the system operates at a 12 V DC drive voltage and monitors the on‑off status of switch contacts to automatically determine pass/fail. For inter‑wire insulation testing and dielectric strength testing, it provides insulation voltages ranging from 100 to 1,000 V DC and withstand voltages from 0 to 5 kV AC or 0 to 6 kV DC, with leakage current limits spanning 0.1 to 20 mA AC or 0.01 to 5 mA DC. Measurement accuracy reaches ±1.5%, meeting stringent safety‑regulation requirements.

For AC charging guns, the ZJ‑CDQ01 comprehensive tester offers an integrated, rapid testing solution. This device is compatible with single‑phase and three‑phase AC charging guns conforming to Chinese, European, and U.S. standards, and provides functions such as insulation resistance, dielectric strength, continuity polarity, and CC/PE resistance testing. The insulation resistance test range spans DC 100–500 V, with a lower limit of 1 MΩ to 10 GΩ and an accuracy of ±5%; the dielectric strength test range covers AC 0–2.5 kV, with a leakage current upper limit of AC 0.1–10 mA and an accuracy of ±1.5%. The system also features audible and visual alarm alerts: when abnormalities such as insulation resistance, dielectric strength, continuity polarity, or resistance exceeding specified limits are detected, the instrument automatically triggers both audible and visual alarms and displays text prompts to help operators quickly identify and resolve the issue.

III. The Importance of Temperature Rise and Thermal Cycling Tests

When operating at high currents, charging guns experience temperature rise; therefore, temperature‑rise testing is a critical step for evaluating a product’s current‑carrying capacity and thermal‑dissipation performance. The ZJ‑WS500A temperature‑rise test system employs constant‑current output technology, enabling stable delivery of test currents ranging from DC 0 to 500.0 A. This approach eliminates the influence of power‑supply voltage fluctuations, connection leads, and variations in the device under test’s resistance, thereby enhancing the accuracy of the test results.

The system supports 30 current and time segments, enabling simulation of complex thermal cycling test scenarios. A touchscreen provides real-time display of current, time, temperature, and temperature–time curves, allowing operators to access data at any moment. The system is equipped with 16 temperature measurement points (including ambient temperature), with a measurement range of 0–200°C and an accuracy of ±1% of reading plus 1°C, ensuring precise monitoring of temperature changes at multiple test locations. Additionally, the equipment features smoke‑detection alarm functionality: when smoke is detected, the alarm is triggered and current output is automatically halted, enhancing test safety.

For products requiring temperature‑rise testing in high‑temperature environments, 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 of ambient to 100°C and a temperature accuracy of ±2°C, meeting the testing requirements of products such as new‑energy wiring harnesses under specific high‑temperature conditions. It delivers a stable, adjustable DC current output from 10 to 1500.0 A, and additionally provides voltage‑drop measurement (0–1000 mV, resolution 0.1 mV, accuracy 1%) and resistance measurement (0–200 mΩ, resolution 0.1 mΩ, accuracy 1%), enabling a comprehensive evaluation of product performance in high‑temperature environments.

IV. Practicality of Life and Mechanical Property Testing

When used outdoors, charging guns must withstand repeated plugging and unplugging after being immersed in corrosive liquids. The charging‑gun insertion‑extraction life‑testing machine (with solution) can automatically cycle the gun through immersion in three types of solutions—rain acid, saltwater, and turbid water—simulating complex outdoor conditions. It then autonomously performs cycles of immersion, insertion/extraction, and energization, replicating the actual service life of a charging gun under outdoor exposure. The equipment is driven by servo electric cylinders, servo modules, and pneumatic cylinders; the insertion/extraction speed is continuously adjustable within the range of 0.1 to 0.80 m/s, meeting the 0.8 ± 0.2 m/s requirement specified in GB/T 20234.1‑2023. The system is equipped with a high‑precision digital pressure module, Maximum The insertion/extraction force is measured up to 500 N, with the computer displaying real-time curves and report data, helping companies accurately assess the mechanical performance of their products.

For applications requiring electrical plug‑in/pull‑out force testing, the ZJ‑CBSM01C charging‑gun durability tester offers a specialized solution. This equipment is compatible with Chinese, European, U.S., and Tesla AC charging‑gun standards and features four interchangeable profiling fixtures for rapid tooling changes. The plug‑in/pull‑out force measurement range is… Maximum 300 N, with a resolution of 0.01 N and an accuracy of 1%, it features an adjustable force‑limit threshold that triggers automatic shutdown and alarm. The system supports data storage via QR code or barcode scanning and binding, automatically generates Excel reports, and can communicate with MES or ERP systems to enable data traceability and system integration. The equipment includes a lifetime‑statistics function, capable of withstanding over 15,000 mating/demating cycles, with customizable cycle counts to meet enterprises’ long‑term durability‑verification requirements.

V. Trends in Intelligentization and Energy Conservation and Environmental Protection

With the advancement of Industry 4.0 and smart manufacturing, the intelligence and energy efficiency of testing equipment have become key areas of development. The ZJ-LH820C AC single- and three-phase charging pile aging test bench employs regenerative load technology to recover electrical energy, feeding the energy generated during testing back to the grid without pollution, thereby conserving resources and preventing the significant heat buildup associated with conventional resistive loads that can raise ambient temperatures. This system supports single-phase AC voltages from 0 to 300 V and three-phase voltages from 0 to 420 V, with continuously adjustable load currents ranging from 1 to 32 A. Each unit features 20 test stations, enabling simultaneous online testing of multiple products.

The system software features intelligent monitoring capabilities, automatically detecting faults or anomalies during the aging process and promptly cutting off power, triggering alarms, and shorting out defective samples, while other stations continue testing to ensure test efficiency. Test data is automatically linked to the product barcode for storage, enabling the generation of electronic reports and supporting integration with MES systems to achieve full‑lifecycle data traceability and quality control.

VI. Selection Recommendations and Summary

When selecting charging gun testing equipment, companies should comprehensively consider the following factors:

ZHONGJIA EQUIPMENT, as a provider of automated intelligent testing systems, focuses on the research, development, and manufacturing of automated, intelligent testing equipment, offering comprehensive testing solutions that cover multiple dimensions, including functional testing, safety compliance testing, life‑cycle testing, and performance validation. By integrating data acquisition, storage, and analysis with MES or ERP systems, ZHONGJIA EQUIPMENT helps customers achieve full‑lifecycle data traceability and quality control, thereby enhancing product quality and market competitiveness.

Against the backdrop of the rapid growth of the new‑energy vehicle industry, the selection of charging‑gun testing equipment not only determines product quality but also shapes a company’s long-term development. Choosing the right testing equipment and establishing a robust quality‑control system are essential for companies to stand out in an increasingly competitive market.