In the research and development and production of new energy vehicle charging facilities, the charging gun comprehensive tester, as a core testing device, plays a crucial role in improving the efficiency of charging interface contact resistance testing through its multi-channel synchronous testing technology. Contact resistance is an important indicator of the electrical connection quality of charging interfaces, and its testing efficiency directly affects production cycle time and quality control levels. Traditional single-channel testing methods require testing the contact resistance of each charging interface individually, resulting in long testing times and low efficiency. Multi-channel synchronous testing technology, by testing multiple interfaces in parallel, significantly shortens the overall testing cycle.
The core of the charging gun comprehensive tester's multi-channel synchronous testing technology lies in the collaborative optimization of hardware architecture and software algorithms to achieve independent operation and synchronous data acquisition of multiple test channels. At the hardware level, the tester adopts a modular design, with each channel equipped with an independent current source, voltage sampling circuit, and signal conditioning module, ensuring that testing of each channel does not interfere with each other. For example, when testing the contact resistance of the charging interface, each channel can simultaneously apply a known current to the terminal under test and collect the voltage drop across the terminal in real time, calculating the contact resistance value using Ohm's law. This parallel testing method avoids the channel switching time in single-channel testing, resulting in a linear improvement in testing efficiency. At the software level, the multi-channel synchronous detection technology relies on high-precision clock synchronization and data acquisition algorithms to ensure the timing consistency of test data across all channels. The tester uses a built-in synchronization signal generator to provide a unified time reference for all test channels, ensuring that each channel acquires voltage and current signals at the same time point, avoiding test errors caused by timing differences. Simultaneously, the software algorithm processes and calibrates the multi-channel data in real time, compensating for measurement deviations caused by hardware differences between channels, further improving the accuracy of test results. For example, when testing the contact resistance of multiple sockets on a charging gun, the software can simultaneously analyze the resistance value of each socket and automatically determine whether it meets standard requirements, reducing manual intervention and data comparison time.
The application of multi-channel synchronous detection technology enables the charging gun comprehensive tester to simultaneously cover multiple key test points of the charging interface. Taking the AC charging interface as an example, it includes multiple contact points such as L1, L2, L3 phase lines, N neutral line, and PE ground line. Traditional testing requires sequentially testing the resistance of each contact point, while multi-channel synchronous detection technology can complete the testing of all contact points at once. This comprehensive testing method not only shortens the testing cycle but also avoids interface wear caused by repeated plugging and unplugging of charging guns, improving testing reliability and repeatability. Furthermore, the tester's multi-channel design supports flexible configuration, allowing adjustment of the number of test channels and test parameters according to the interface specifications of different charging gun models, meeting diverse production needs.
On the production line, multi-channel synchronous testing technology, through integration with automated testing systems, further improves the efficiency of charging interface contact resistance testing. The tester can be linked with automated equipment such as robotic arms and conveyors to achieve automatic loading, unloading, and positioning of charging guns, reducing manual operation time. Simultaneously, the tester supports data interaction with the Manufacturing Execution System (MES), uploading test results to the database in real time, providing data support for production traceability and quality control. For example, when the contact resistance test data of a batch of charging guns is abnormal, the system can automatically mark the problematic products and trigger an alarm mechanism, guiding production personnel to adjust process parameters in a timely manner to avoid batch quality problems.
Multi-channel synchronous testing technology also brings higher testing accuracy and stability to the charging gun comprehensive tester. Because each test channel operates independently, testing errors caused by current source load variations, common in single-channel testing, are avoided. Simultaneously, the synchronous data acquisition algorithm effectively suppresses electromagnetic interference and noise, improving the signal-to-noise ratio of voltage and current signals, making the contact resistance measurement results closer to the true value. This high-precision testing capability provides a reliable basis for assessing the electrical safety of charging guns, ensuring stable electrical connection performance of the charging interface during long-term use.
The multi-channel synchronous testing technology of the charging gun comprehensive tester, through collaborative innovation in hardware parallelization, software synchronization, and production automation, significantly improves the testing efficiency of charging interface contact resistance. It not only shortens the testing cycle and reduces production costs but also provides strong support for the quality control and performance optimization of charging guns through high-precision, full-coverage testing capabilities. With the rapid development of the new energy vehicle industry, multi-channel synchronous testing technology will become a core competitive advantage for charging gun comprehensive testers, driving charging infrastructure towards higher efficiency and reliability.
