How an EV Charging Connector Manufacturer Improved Testing Consistency with Sinuo's Insertion & Withdrawal Force Tester

As the global electric vehicle market continues to expand, manufacturers of EV charging connectors are facing increasingly stringent quality and compliance requirements. One of the most critical mechanical performance tests is the insertion and withdrawal force test, which directly affects user experience, connector durability, and compliance with international standards.

Recently, Sinuo Testing Equipment supplied an EV Charging Plug Insertion & Withdrawal Force Testing Machine to a customer specializing in EV charging connectors. The goal was straightforward: achieve accurate, repeatable, and fully automated force testing while reducing operator influence during routine inspections.

👉 Learn more about the product here:
www.sinuotek.com/sale-55467876-iec-62196-1-2014-compliant-ev-plug-insertion-and-withdrawal-force-tester.html

The customer was previously relying on manual force gauges and semi-automatic fixtures to verify connector performance. While this method was acceptable for small-scale inspections, several issues became increasingly apparent as production volumes increased:

• Test results varied between operators.
• Recording peak insertion and extraction forces required manual intervention.
• Historical test data was difficult to organize and trace.
• Compliance with international certification standards required more precise measurement equipment.

To improve efficiency and ensure consistent quality, the customer decided to upgrade to an automated testing solution.

After reviewing the customer's testing requirements, our engineering team recommended the Servo-Controlled EV Charging Connector Insertion & Withdrawal Force Tester, designed specifically for IEC 62196-1 compliance testing.

Unlike conventional manual systems, the equipment combines a servo motor, PLC intelligent control, and a high-precision force sensor to provide smooth, repeatable testing throughout the entire insertion and extraction process.

The system continuously records the force curve, automatically captures peak values, and stops the test once the preset force limit is reached, eliminating operator subjectivity.

Several features were especially valuable during the customer's evaluation:

The tester measures forces from 10 N to 1000 N with ±0.5% accuracy, allowing the customer to validate various connector models using a single machine.

Instead of relying on manual movement, the servo-driven mechanism provides highly repeatable movement speeds ranging from 0.01 to 100 mm/min, ensuring every test follows identical conditions.

Force-displacement curves are displayed in real time, while test data can be exported directly via USB for quality documentation and certification reports.

The supplied fixture was designed specifically for CCS2 charging interfaces, reducing setup time and improving positioning accuracy.

After the equipment was commissioned, the customer reported several noticeable improvements:

• Significantly improved consistency between repeated tests.
• Faster testing workflow thanks to automated operation.
• Easier quality documentation with digital data export.
• Reduced operator training requirements.
• Greater confidence during internal quality audits and certification testing.

According to the customer, the new system has become one of the most frequently used pieces of equipment in their mechanical testing laboratory.

As EV charging standards continue to evolve, manufacturers require testing equipment capable of delivering both precision and long-term reliability.

Sinuo's testing solution supports routine quality inspection, product development, certification laboratories, and endurance verification for various EV charging connector designs.

Typical applications include:

• EV charging plugs
• Vehicle inlets
• CCS2 connectors
• Charging sockets
• Locking mechanism evaluation
• Mechanical durability verification

Whether you're developing next-generation charging connectors or upgrading your laboratory, selecting the right testing equipment can significantly improve both testing efficiency and product consistency.

Explore our complete EV charging testing solutions here:

👉 EV Charging Connector Insertion & Withdrawal Force Tester

Or browse more IEC 62196 testing equipment on our website:

👉 https://www.sinuotek.com/supplier-353625-vehicle-testing-equipment

Sinuo specializes in the design and manufacture of IEC, UL, ISO, and GB standard testing equipment for electrical appliances, EV charging systems, consumer electronics, and laboratories worldwide. With years of industry experience and customized engineering capabilities, we help manufacturers simplify compliance testing while improving product quality and operational efficiency.