Charging Gun Plug-In Life Testing Machine

Charging Gun Plug-In Life Testing Machine

ZJ-CBSM01
This equipment is suitable for the charging gun plug and socket breaking capacity and normal operation life test, locking device test, and plug-in force test. It uses servo electric cylinders, servo motors, air cylinders, etc. as power, and a small fixture to clamp the sample. The touch screen and programmable controller (PLC) are the control center. It has superior performance, easy operation, and a high degree of automation. It can clamp the charging gun, automatically immerse the charging gun in acid rain solution, saline solution, and muddy water solution in turn, and then automatically take it out and insert it into the charging gun holder. The last power-on is 1.5 hours, and the action is repeated to simulate the plug-in life of the charging gun outdoors. All test items meet the requirements of GB/T18187.1-2015, GB/T20234.1-2023, and GB/T11918.1-2014.

Consult

Features
Technical Indicators
Overall Dimension

This equipment is equipped with computer control software and laptop computer.
1. It has computer remote control function and can operate DC power load simulator through computer software (power supply and load need to improve communication protocol MODBUS RTU).
2. The parameters set in the computer software are sent to the DC power load simulator through the communication line. The DC power load simulator runs according to the set parameters and transmits the actual current and voltage data back to the computer in real time.
3. The test system can perform real-time data observation and data playback, waveform saving function, and waveform acquisition frequency 1K (only when connected, no acquisition when not connected).
4. With multi-channel temperature monitoring function, the system power supply can be quickly cut off when the temperature is abnormal.
5. The software meets the hardware free combination to form multi-channel low-power use and single-channel high-power use (the load machine needs this function).
6. The system is equipped with an emergency stop alarm device.
7. Safety protection: The equipment has electrical safety that meets the requirements of national standards, which can effectively prevent and eliminate the possible electric shock hazards of operators and maintenance personnel. During normal operation, except for the circuit part of the equipment, the outer shell of the equipment, the metal parts in the test box, etc. will not be charged.
Panel Description

Figure 1 Control Panel

① Forward button: Press the gun head fixture to move forward Computer control: Set parameters and monitor
② Back button: Press the gun head fixture to move back
③ Start button: Machine operation
④ Turn left: The gun head fixture turns left
⑤ Turn right: The gun head fixture turns right
⑥ Stop button: Machine stop
⑦ Manual cylinder button: Press down cylinder control
⑧ Emergency stop button: Emergency stop
⑨ Power switch: Switchboard power switch
⑩ USB interface: Export data

Figure 2 Mechanical composition

⑪ Slide handwheel: Left and right fixture adjustment
⑫ Slide handwheel: Upper and lower fixture adjustment
⑬ Charging gun seat
⑭ 4 liquid tanks (pour different solutions)
⑮ Press down cylinder: Press cylinder Charging gun holder fixture
⑯ Charging gun head sample installation
⑰ Pressure sensor
⑱ Charging gun head fixture
⑲ Threshold switch

Operation instructions
1. Connect the side of the device to the external AC220V control power supply, and the air source to the external 0.4~0.6MPa air pressure.
2. Turn on the panel "power switch" and open the charging gun life test software.exe on the computer desktop. Enter the computer "parameter monitoring" interface: the 4 indicator lights in the upper right corner show green, indicating normal communication.

Figure 4

Number of plugging and unplugging: total plugging and unplugging count
Plugging and unplugging stroke: plugging and unplugging stroke
Timer: plugging and unplugging test time
Plugging and unplugging force display: real-time insertion force or extraction force
Maximum insertion force: maximum instantaneous force value for insertion
Maximum extraction force: maximum instantaneous force value for extraction
Zero: reset key for clearing data on the left
AB phase voltage: display current voltage value (V)
B phase voltage: display current voltage value (V)
C phase voltage: display current voltage value (V)
A phase current: display current current value (A)
B phase current: display current current value (A)
A phase power: display current power value (W)
B phase power: display current power value (W)
C phase power: display current power value (W)
Power factor: display current power factor value
Temperature: Temperature 1~Temperature 16: real-time temperature display value (degrees) from the first to the 16th channel
Reset button: reset alarm information
Automatic return: return to zero position
L1 no current: L1 no current alarm light
L2 no current: L2 No current alarm light
L3 no current: L3 no current alarm light
N no current: N no current alarm light
L1 is not disconnected: L1 circuit is not disconnected after the gun head is pulled out, the alarm light
L2 is not disconnected: L2 circuit is not disconnected after the gun head is pulled out, the alarm light
L3 is not disconnected: L3 circuit is not disconnected after the gun head is pulled out, the alarm light
N is not disconnected: N circuit is not disconnected after the gun head is pulled out, the alarm light
Front/rear threshold: front limit/rear limit indicator light
Door opened: door open status indicator light
Count to: number of times reached indicator light
Emergency stop: emergency stop status light display
Plugging and unplugging servo: servo drive status alarm light
Test: set count, plug-in speed, insertion time, test rate (times/minute), alarm time, button disconnection time. Select the test mode. Press Auto Return to return to the zero position. Press the Reset button to clear the alarm information. Clear the test count and switch count. At this time, press the Start button on the control panel. The equipment starts to run the test according to the set parameters. Until the test count reaches the stop.
3. Enter the computer "Alarm Information" interface:

Figure 5

Alarm information: Display the specific date and time and alarm reason information
4. Enter the computer "Plug and unplug parameter setting" interface:

Figure 6

Count setting: Set the total number of plug and unplug tests
Plug and unplug speed: Set the speed of plug and unplug operation
Plug and unplug stroke: Set the plug and unplug stroke MM
Insert time: Charging gun insertion time: 1~999.9s can be set
Alarm time: Set the display alarm time
Test rate: Set the unplug test rate (times/min)
Mode selection: Plug and unplug mode: Independent test plug and unplug, record the total number of plug and unplug
Temperature rise mode: Independent test temperature rise, no counting
Plug and unplug + temperature rise: Single test plug and unplug, then test temperature rise
L1 detection: L1 current detection switch
L2 detection: L2 current detection switch
L3 detection: L3 current detection switch
Gate detection: Open the threshold switch and display it in green
Load voltage and current selection formula
Voltage setting: After pressing the call-out button, the preset voltage is displayed
Current setting: After pressing the call-out button, the preset current is displayed
(+) sign: Recipe increment
(-) sign: Recipe decrement
Recipe selection: Change the number by (+) or (-). The number is an independent recipe (see manual control for setting). During the temperature rise test, click the Call Out button on the right to wake up the recipe. The test is based on this recipe.
Before the test, you can change the recipe by + or -. After pressing the Call Out button to wake up the recipe, the saved current setting and voltage setting values will be displayed at the top. Press the output button, the load is connected and the actual current and voltage values are displayed. For those without ready-made formulas, a new formula needs to be combined. The method is as follows: For example, set a 6V 250A formula. Use the + or - key to select a formula number without data, set the voltage setting to 6V, set the current setting to 250A, select a resistance current range of 500A or 200A+200A+100A, and click the Output button. After the upper voltage display rises to 6 volts, connect the load. At this time, the current displays the actual value. If there is an error between the actual current value and the set value, press the Stop Load button. After disconnecting the load, increase or decrease the current range appropriately, and then press the Output button to observe the actual current and the set current. Repeat the previous action until the actual current is consistent with the set current. After stopping the output load, press the Save button to save the formula.
Save: Click to save the recipe
Start the load: Connect the load
Stop the load: Disconnect the load
5. Enter the computer "Temperature Curve" interface:

Figure 7

Temperature 1~Temperature 16: Temperature 1~Temperature 16 curve color, point the mouse at the curve as shown in Figure 4 above, right-click the mouse, select Curve Visible (check mark in front), then the curve can be seen in the left frame, no check mark to close the curve. Click the blank space of the temperature Y axis as shown in Figure 2 above, click the right mouse button Y automatic zoom (check mark in front), then the temperature Y axis will automatically zoom according to the temperature size.
As shown in Figure 1 above, curve zoom in and out: In the stopped state, temperature Y axis, click the minimum and maximum values, and enter the corresponding values on the keyboard to zoom in or out the temperature curve.
As shown in Figure 3 above, time curve: In the stopped state, time X axis, click the minimum and maximum values, and enter the corresponding values on the keyboard to zoom in or out the curve.
As shown in Figures 5 and 6 above, current/voltage curve: In the stopped state, the current/voltage Y axis, click the minimum and maximum values, and enter the corresponding values on the keyboard to enlarge or reduce the curve.
Curve export: In the stopped state, the mouse corresponds to the frame, right-click the mouse and select Export to Excel. Then a spreadsheet will be automatically generated.
Curve clearing: The mouse faces the frame, right-click the mouse, and select Clear curve.
Collect data: The green light indicates that the data collection is turned on
Interval (milliseconds): Temperature collection interval
6. Enter the computer "Force Curve" interface:

Figure 8

The curve color is displayed in the upper left corner of the curve: plug-in and pull-out times, maximum insertion force, maximum pull-out force, click the corresponding curve color with the mouse, right-click to choose to open or close the curve, and select the curve to be visible (with a check mark in front).
In the stopped state, changing the Y-axis force value, the maximum and minimum plug-in and pull-out times can enlarge or reduce the curve, and changing the maximum and minimum X-axis collection times can also enlarge or reduce the curve. Curve export: In the stopped state, the mouse corresponds to the frame, right-click the mouse and select Export to Excel, and a spreadsheet will be automatically generated.

Collection times - plug-in times (1/3/5 columns): represents the curve collection point. Force value N - plug-in times: represents the plug-in times. Force value N - maximum insertion force: represents the maximum insertion force. Force value N - maximum extraction force: represents the maximum extraction force.
Curve clear: point the mouse at the frame, right-click the mouse, and select clear curve.
7. Enter the computer "Manual Control" interface:

Figure 9

Plug-in force display: current plug-in force value
Plug-in position display: current plug-in position
Plug-in stroke setting value: current plug-in stroke distance data
Test mode: select test mode
Zero point confirmation: press this button, and the plug-in position is displayed as 0. During the test, the current position will be used as the starting point to start the operation.
Manual speed: divided into three levels, fast/slow/very slow. When moving manually, it will run at the set level.
Button release: manually release the gun head button, and the gun head can be pulled back.
8. Enter the computer "Voltage and Current Waveform" interface:

Figure 10

The current voltage and current waveforms are displayed in the upper right corner of the curve. Click the corresponding curve color with the mouse. Right-click to open or close the curve. The selected curve is visible (with a check mark in front).
Each channel (point): 0~100 points can be selected.
Start/stop acquisition: After the automatic storage after insertion is checked, the data will start to be stored in the computer mobile disk. Click to stop acquisition after the test.
Single-point acquisition: Select single-point acquisition waveform
Continuous acquisition: Select multi-point continuous acquisition waveform
9. Enter the computer "View Waveform" interface:

Figure 12
Open the computer mobile disk to view the voltage and current waveform records
10. Enter the computer "dubug" interface.

Figure 11

About current calibration Point the mouse to the PLC communication light and press the CTRL key on the keyboard at the same time to enter the calibration interface shown below. Change the coefficient to change the displayed value.

Figure 12

(Front wiring port Gun seat wiring port left Gun head wiring port right)
(Back wiring port Load power input right, load input left)

Figure 13

X axis: Gun seat bracket moves left and right
Y axis: Gun seat bracket moves up and down
Sample installation Fix the sample gun head on the gun head bracket, as shown in Figure 13, so that the gun head remains horizontal and fixed. Adjust the slide handwheel to keep the gun seat mouth and the gun head mouth of the slide in the same straight line and in the right position. Select manual control, click the button to release, and adjust the button cylinder bracket so that the front end of the button cylinder presses the gun head button in place. At this time, fix the cylinder bracket, fix the gun seat on the gun seat bracket, manually control the software interface to select the appropriate speed, press the forward button on the side panel, make the gun head move forward slowly, observe the gap between the gun seat mouth and the gun head, adjust the X and Y axes of the gun seat bracket, make the gun head mouth evenly align with the gun seat, until it is inserted into the appropriate position of the gun seat, and then fix the gun seat screw. Press the zero point confirmation button on the side panel for 2 seconds, and the current position is zero. You can also press the position set to zero button in the software interface to set the zero point, and then press the back button on the side panel to make the gun head slowly back to the appropriate position. Record the distance data of the plug-in position display on the current manual control interface. Press the zero point confirmation button again, and the distance displayed on the plug-in position on the manual control interface is 0. Write the plug-in stroke on the parameter setting interface to the data just now, and the positioning is completed.
Plug-in test: Enter the parameter setting, select the plug-in test in the test mode, set the test parameters: plug-in times, upper and lower limits of the maximum plug-in force, insertion time, removal time, etc., turn on the conduction detection switch, and clear the force value curve data.
Plug and unplug + temperature rise test: Enter parameter setting, select plug and unplug + temperature rise test in test mode, set test parameters: single plug and unplug times, number of cycles, total plug and unplug times. Maximum upper and lower limits of plug and unplug force, insertion time, removal time, upper temperature limit, etc. Turn on the conduction detection switch. Press the call-out button to wake up the test formula of the load voltage and current formula (the formula combination is introduced earlier). Set the temperature rise test time, clear the data of the force curve, set the acquisition interval time of the temperature curve, and clear the curve data.
Temperature rise test: Enter parameter setting, select temperature rise test in test mode, and set test parameters: upper temperature limit. Press the call-out button to wake up the test formula of the load voltage and current formula (the formula combination is introduced earlier). Set the temperature rise test time. Set the acquisition interval time of the temperature curve, clear the curve data. Press ZERO on the parameter monitoring interface to clear the temperature rise test time, etc. Manually press the forward button on the side panel, wait for the gun head to be inserted into the appropriate position of the gun seat, and press the start button on the panel, then the constant current source outputs voltage and current until the set test time stops. The parameter monitoring indicator or alarm light shows the current shutdown status. Press the reset button on the panel to reset the alarm or indicator light and proceed to the next test. When the test is completed, the required data can be exported on the corresponding interface.
1) Meet the test of applying 200N pull-out force to the locking device
2) Meet the plug and socket insertion and pull-out force test
3) Meet the plug and socket breaking capacity and normal operation life test
4) Test station: 1 station
5) Detection mode: 2p+E, 3P+E, 3P+E+N and other specifications
6) Operation interface: 10-inch Weiluntong touch screen
7) PLC: Mitsubishi FX5U
8) Drive mode: bus-type servo motor, support CC-Link/EtherCat communication
The servo motor drives the ball screw to rotate and the slide rail is used as a guide to make the fixture plug and unplug. The fixture has another servo motor for rotation. The charging gun can be rotated and immersed in the solution. After immersion, it automatically rotates to the plug-in position.
9) Test times: 0~999999 times, preset
10) Current conduction time: 0~999.9s preset
11) Disconnection time: 0~999.9s preset
12) Product immersion time: 1~9999s settable.
13) Plug-in stroke: 0~450mm arbitrarily set, resolution 0.1mm:
14) Device structure: The test device is placed horizontally, welded with a national standard 40mmx40mm square tube frame, and the sealing plate is CNC machined with a 1.2mm Baosteel electrolytic plate.

15) Controller: The system uses a 10-inch touch screen and a programmable controller (PLC) logic intelligent control device. Each test parameter can realize the storage function, simple operation, easy to use, and greatly improves efficiency.
16) Plug-in force: maximum 600N, high-precision digital pressure module, computer force value curve display, report display plug-in force value, data saved in Excel format.
17) Alarm function: connection timeout, disconnection timeout, over-temperature protection, detection times reached, etc.
18) Power interface: AC power interface uses 4 12mm copper screws, DC power interface uses 2 12mm copper screws.
19) Load interface: AC load interface uses 4 12mm copper screws, load power interface uses 2 12mm copper screws.
20) Installation results: The gun mount is fixed with a three-axis adjustable base, plus the national standard, American standard and European standard AC and DC gun mounts, a total of 6 fixed seats.
The gun head is clamped by 3 clamps of different sizes.
21) Unlocking function: There are two modes, one is to press the gun before pulling it out, and release it after pulling it out
The other is to keep pressing it
22) Action speed: The speed of plug or connector insertion and removal is (0.1~0.80) m/S arbitrarily set [fully meet the standard requirement of 0.8±0.2) m/s
23) Manual adjustment, the system has a manual condition button to facilitate the clamping of the sample
24) Alarm detection: Following the principle of "must be connected when it should be connected, and must be disconnected when it should be disconnected", the system determines whether the sample is damaged based on the logical relationship between "position and current". When the sample under test is damaged, the equipment can issue an audible and visual alarm prompt and automatically shut down.
25) There are four liquid tanks containing different solutions. The equipment automatically moves the unconnected solution tank to the bottom of the charging gun, and the charging gun automatically soaks in different solutions.
26) Test process:
a. Soak the gun tip in a bucket of rain acid solution for 4~5 seconds, then take it out and automatically plug it in and out for 10 cycles.
b. Then soak the gun tip in a bucket of salt water solution for 4~5 seconds, then take it out and automatically plug it in and out for 10 cycles.
c. Then soak the gun tip in a bucket of turbid water solution for 4~5 seconds, then take it out and automatically plug it in and out for 10 cycles.
d. Then energize the gun tip and gun holder for 1.5 hours.
Repeat a~d 20 times
The test step is completed automatically by the equipment
27) Equipped with power load, 220VAC/380V/50Hz meets the three-phase/single-phase charging pile test (see the power load section for parameters)
28) Voltage and current setting range: DC voltage 1500V, current 20A, (see the power load section for parameters)
29) AC voltage three-phase 380V, AC current 1-100A adjustable, (see the power load section for parameters)
30) Power factor: 0.5-1.0 adjustable, (see the power load section for parameters)
31) Resistance quality: ceramic chip resistors or resistors with large heat dissipation area
32) Leakage protection: Install a leakage switch at the control power supply line of the equipment. When leakage occurs, cut off the control power supply to cut off the power of the entire cabinet:
33) Overcurrent protection: Each station is protected by a fuse (circuit breaker) to prevent overcurrent or short circuit in the circuit.
34) Overload protection: The equipment is equipped with a circuit breaker that can automatically trip when overload occurs.
35) Threshold protection: All movable cabinet doors are equipped with safety protection switches. When the cabinet door is opened, the power supply is automatically cut off to prevent the operator from being exposed to the risk of electric shock.
36) Emergency stop switch: The power cabinet control panel has an emergency stop switch, which is convenient for the operator to cut off the output power of the power cabinet when an abnormality occurs or when necessary:
37) In and out leads: The input and output lead ports are covered with protective coils to prevent the cables from being damaged.
38) Life machine dimensions: about W1800mmxD900mmxH1650mm
39) Weight: about 350Kg
40) Working power supply: AC220V±10%, 50Hz, 20A.

Equipment safety part
1) Threshold protection: All movable cabinet doors are equipped with safety protection switches. When the cabinet door is opened, the power supply is automatically cut off to prevent the operator from being exposed to the risk of electric shock.
2) The cooling fan uses a cabinet-specific fan, with shutters and filter cotton on the outside and wire mesh on the inside (inlet and outlet signs are required)
3) The transmission mechanism has a protective cover and a transparent window for viewing.
4) The machine noise is less than 80 points
The overall picture is for reference only, please refer to the actual situation
Charging gun plug-in life test machine picture
Figure (1) is for reference only, please refer to the actual object
41) Drive device: Provides standard mechanical movements for the test system
42) Device structure: The test device is placed horizontally and is welded with a national standard 40mmx40mm square tube frame. The sealing plate is CNC machined from 1.2mm Baosteel electrolytic plate.
43) Controller: The system uses a 10-inch touch screen and a programmable controller (PLC) to control the operation of the device
44) When the control plug is inserted, the power supply output and the load output can be controlled through 485 communication. When the rated current and the connection time are reached, it is automatically unplugged. It can control 2 power supplies and 2 loads.
45) All test parameters can be stored in the event of power failure, especially the control power supply and load can be set to 5 different formulas, which can be directly called when needed without resetting. It is simple to operate and easy to use, which greatly improves efficiency.
46) Capacity range: It can meet the three-phase or single-phase test of all 2p+E, 3P+E, 3P+E+N and other specifications, AC rated current ≤250A or DC ≤400 socket (plug) products,
47) Action speed: The speed of plug or connector insertion and removal is (0.1~0.8) m/S, which can be set arbitrarily [fully meet the standard requirement of 0.8±0.1) m/s
48) Test rate: The speed of plug or connector insertion and removal from the socket or appliance input socket is 7.5 strokes per minute:
49) Manual adjustment: The system has a manual condition button to facilitate the clamping of the sample:
50) Electrical contact time: 2S<.t≤4, which can be fine-tuned.
51) Drive system: Servo motor drive + ball screw rotation and silent slide rail as guide to make the fixture reciprocate left and right, which can provide a maximum insertion and removal force of 500N
52) Insertion and removal stroke: 0~200mm arbitrarily set (i.e. the stroke of the left fixture driven by the servo motor), resolution 0.1mm:
53) Distance between two fixtures: Max450mm (excluding samples), fully meeting the standard requirement of "two electrical appliances should be separated by at least 50mm":
54) Test fixture: meet the requirements of Figure 5 of GB 11918.1-2014 standard, including
55) The clamping range of three-phase plugs, sockets and connectors is square 100mm×100mm, round φ100mm.
56) The central holding range of single-phase plugs, sockets and connectors is square 100mm10mm, round φ100mm:
57) The plastic shell sample fixture uses a metal fixture.
58) Test station: 1 station is independent
59) Test times: 1~9999 times can be set arbitrarily, and the machine can automatically stop when the count reaches the set value:
60) Leakage protection: A leakage switch is installed at the control power supply line of the equipment. When leakage occurs, the control power is cut off to cut off the power of the entire cabinet:
61) Overcurrent protection: Each station is protected by a fuse (circuit breaker) to prevent overcurrent or short circuit in the circuit.
62) Overload protection: A circuit breaker is installed inside the equipment, which can automatically trip when overload occurs.
63) Threshold protection: All movable cabinet doors are equipped with safety protection switches. When the cabinet door is opened, the power supply is automatically cut off to prevent the operator from being exposed to the risk of electric shock.
64) Emergency stop switch: The power cabinet control panel has an emergency stop switch, which is convenient for operators to cut off the power supply of the power cabinet when an abnormality occurs or when necessary:
65) Input and output leads: The input and output lead ports are covered with protective coils to prevent the cables from being damaged.
66) This equipment does not include load power and load.
67) Dimensions: about W1400mmxD1000mmxH1500mm
68) Weight: about 250Kg
69) Working power supply: AC220V±10%, 50Hz, 20A.