New Energy Vehicle Charging Gun Testing

With the rapid adoption of new energy vehicles, the charging gun, serving as a critical component connecting vehicles to charging stations, plays a pivotal role in ensuring safe charging. To meet the demands of everyday use, rigorous testing and certification of charging guns are essential. China’s JJR Laboratory, a professional third-party testing organization, has introduced a full suite of testing equipment, enabling comprehensive testing and certification services for charging guns in accordance with various domestic and international standards.

Core Testing Equipment for Charging Guns

- Vehicle Overrun Testing Machine  

- Charging Interface Cable Flexing Tester  

- Mechanical Strength Testing Equipment for Charging Guns  

- Plug-and-Unplug Lifecycle Tester  

- Resistive and Inductive Load Bank  

- High-Power Power Supply System  

Charging Gun Testing Standards

China’s JJR Laboratory conducts charging gun testing based on multiple standards to ensure compliance with all performance requirements. Common testing standards include:  

- IEC 62196-1:2022: Plugs, socket-outlets, vehicle connectors, and vehicle inlets – Conductive charging of electric vehicles – Part 1: General requirements.  

- IEC 61851-1:2017: Electric vehicle conductive charging system – Part 1: General requirements.  

- UL 2251:2020: Plugs, receptacles, and connectors for electric vehicles.  

- GB/T 20234.1-2023: Connection devices for conductive charging of electric vehicles – Part 1: General requirements.  

- GB/T 20234.2-2023: Connection devices for conductive charging of electric vehicles – Part 2: AC charging interface.  

- GB/T 20234.3-2023: Connection devices for conductive charging of electric vehicles – Part 3: DC charging interface.  

- GB/T 18487.1-2022: Electric vehicle conductive charging system – Part 1: General requirements.  

Leveraging advanced testing equipment and a professional technical team, JJR Laboratory provides comprehensive testing services for charging guns’ performance and reliability metrics in line with standards such as IEC 62196-1:2022.

Through rigorous testing, JJR ensures charging guns meet mechanical, electrical, and environmental performance standards, safeguarding the safety of electric vehicle charging. Whether during product design and development or pre-market quality verification, JJR Laboratory offers all-encompassing technical support to help enterprises enhance product quality and maintain market competitiveness.

Charging Gun Testing Categories

1. General Requirements  

- Appearance and Structural Requirements: Ensures the charging gun’s appearance meets standards, has no defects, and features robust construction.  

- Dimensional and Type Requirements for Charging Interfaces: Verifies that interface dimensions comply with standards to ensure compatibility with different charging equipment.  

- Screws, Current-Carrying Components, and Connection Requirements: Ensures the firmness of screws and connections for safe current transmission.  

- Terminal and End Requirements: Evaluates the quality of terminals and ends to ensure stable electrical connections.  

- Electric Shock Protection Requirements: Tests anti-electric shock measures to ensure user safety during operation.  

2. Electrical Performance  

- Grounding Measures: Evaluates the grounding system to ensure safe electrical grounding.  

- Breaking Capacity: Assesses the gun’s ability to break the circuit under overload conditions.  

- Surface Temperature: Monitors surface temperatures during operation to prevent overheating risks.  

- Temperature Monitoring Requirements: Tests the system's ability to detect and respond to temperature anomalies.  

- Insulation Resistance and Dielectric Strength: Ensures electrical safety under various environmental conditions.  

3. Durability Testing  

- Locking Mechanism Durability: Evaluates the durability of locking mechanisms for stable performance over prolonged use.  

- Normal Operation Durability (Lifespan): Simulates usage scenarios to test durability after repeated plug-and-unplug cycles.  

- Contact Durability: Assesses the durability of connectors to ensure consistent contact during frequent use.  

- Switch Component Durability: Tests the longevity and reliability of internal switch components.  

4. Environmental Reliability  

- High and Low Temperature Resistance: Simulates extreme temperature conditions to test resilience.  

- Humidity Resistance: Evaluates performance under high-humidity conditions.  

- Temperature Shock: Assesses stability under rapid temperature changes.  

- IP Protection Rating: Tests dust and water resistance for reliability in harsh environments.  

5. Mechanical Reliability  

- Vehicle Overrun Test: Simulates the mechanical strength of the charging gun under vehicle pressure.  

- Cable Connection Strength (Tension and Torsion Test): Evaluates connection strength under stress.  

- Mechanical Strength (Pendulum Impact, Flexing, etc.): Ensures impact and bending resistance during usage.  

- Vibration/Shock Testing: Simulates vibrations and shocks during transportation and use.  

- Offset Operation Test: Assesses mechanical performance under improper operations.  

6. Material Testing  

- Aging Resistance of Rubber and Thermoplastic Materials: Tests material durability over time to ensure longevity.  

- Corrosion and Rust Resistance: Assesses the outer shell’s ability to resist corrosion and rust in harsh environments.  

- Heat, Flame, and Tracking Resistance: Tests material performance under extreme conditions.  

- Restricted Substances Testing (ELV, ROHS, SOC, etc.): Ensures materials are free of hazardous substances and meet environmental standards.  

Why Choose JJR Laboratory?  

1. Brand Trust: Established in 1998, recognized by CNAS and CMA, and designated as a National SME Public Technology Service Platform.  

2. Comprehensive Certifications: Recognized by multiple domestic and international organizations with widely trusted testing reports.  

3. International Standards: Operates in compliance with ISO/IEC 17025 and over 10 international and domestic standards.  

4. Service Excellence: Provides efficient, one-stop testing and certification services, trusted by numerous renowned domestic and international enterprises.