IEC 62196-1 EV Plug Drive-Over Crushing Test Equipment For Vehicle Connector Crushing Test
The EV Plug Drive-Over Test Equipment is designed to evaluate the mechanical durability and safety of electric vehicle connectors and plugs under vehicle crushing conditions. This system simulates real-world scenarios where EV charging connectors may be accidentally run over by a vehicle, ensuring compliance with international safety standards.
Engineered for precision and reliability, this equipment is widely used in EV charger manufacturers, testing laboratories, and certification bodies for EV connector durability testing, charging plug safety validation, and compliance testing.
- Fully compliant with IEC 62196-1:2022 Clause 33 and UL 2594 Clause 58
- Realistic simulation of vehicle tire rolling over EV connectors
- Adjustable crushing force up to 11000N
- High-precision PLC control system with touchscreen interface
- Heavy-duty structure with industrial-grade motor and reducer
- Simulated concrete test surface for accurate testing conditions
- Bidirectional rolling simulation (forward & reverse)
- Enhanced safety system with protective enclosure and interlocks
The equipment simulates a vehicle driving over an EV plug or connector placed on a concrete surface. A specified load is applied using a standard automotive tire under controlled speed and pressure conditions.
- Rolling speed: 8 ±2 km/h
- Tire type: P225/75R15 or equivalent
- Tire pressure: 2.2 ±0.1 bar
- Crushing force:
- 5000 ±250 N
- 11000 ±550 N
- 4893 N (UL standard)
The system ensures that the sample remains fixed while undergoing repeated rolling cycles, replicating real-life stress conditions.
- IEC 62196-1:2022 Clause 33
- UL 2594:2016 Clause 58
| Item | Specification |
|---|---|
| Test Station | Single station |
| Control System | PLC intelligent control + 7-inch touchscreen |
| Operation Mode | Automatic / Manual switchable |
| Drive System | Motor + worm gear reducer |
| Drive Stroke | 0-2.0 m |
| Drive Speed | 8±2 km/h (adjustable) |
| Crushing Force | A. Crushing force (5000±250) N B. Crushing force (11000±550) N C. Crushing force 4893 N (1100 lbf) |
| Force Adjustment | Weight loading system (4890-11000 N) |
| Tire Type | P225/75R15 + load-bearing tire |
| Tire Pressure | 220±10 kPa / 218±13 kPa |
| Rolling Method | Linear motor reciprocating motion |
| Base Plate | Simulated concrete floor with fixtures |
| Display | Touchscreen parameter setting & monitoring |
| Braking System | Built-in anti-collision braking mechanism |
| Power Supply | AC 480V ±10%, 60Hz, 15 kW |
| Dimensions | Approx. 4700 × 1300 × 3000 mm |
| Weight | Approx. 2400 kg |
The equipment features a robust cold-rolled steel enclosure with Teflon-coated surface for corrosion resistance. The internal structure integrates stainless steel and aluminum components to ensure long-term durability.
The rolling mechanism is guided by heavy-duty rails and powered by a high-torque motor system, ensuring smooth and consistent operation. The adjustable weight system allows precise control of crushing force, while the integrated crane arm simplifies loading operations.
- Fully enclosed protective structure
- Mechanical crane arm for safe weight handling
- Leakage protection switch
- Motor overload protection
- Safety door interlock system
- Anti-deviation wheel protection system
- EV charging plug and connector testing
- Electric vehicle supply equipment (EVSE) validation
- Product certification testing laboratories
- Quality inspection and R&D testing
The drive-over test evaluates whether an electric vehicle (EV) plug or connector can withstand mechanical damage when accidentally run over by a vehicle. This ensures product safety and durability in real-world usage scenarios.
This equipment fully complies with:
- IEC 62196-1:2022 Clause 33
- UL 2594:2016 Clause 58
It is suitable for global EV charging connector compliance testing.
The equipment is designed for:
- EV charging plugs
- Vehicle connectors
- EVSE (Electric Vehicle Supply Equipment) accessories
- Charging cable assemblies
The system supports multiple force levels:
- 5000±250 N (IEC standard)
- 11000±550 N (IEC high load condition)
- 4893 N (UL requirement)
The force can be adjusted using a calibrated weight system.
Yes, the rolling speed is adjustable via the motor control system, with a standard testing speed of 8 ±2 km/h as required by IEC and UL standards.
The system is equipped with:
- Standard P225/75R15 automotive tire
- Load-bearing tire for higher force conditions
Both are mounted on steel rims and inflated according to standard requirements.
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