Testing device and testing method for cable joint of new energy automobile

Abstract

The invention discloses a test device and a test method for a cable joint of a new energy automobile, and relates to the technical field of cable joint test.The test device comprises a base used for supporting a charging socket and a charging gun, the charging gun is provided with a tongue pressing block and an elastic button used for controlling the tongue pressing block to retract, and the charging socket is provided with a tongue groove used in cooperation with the tongue pressing block in a clamped mode. The base is provided with a compounding mechanism, the compounding mechanism comprises a spline shaft fixedly connected to the base, and the base is provided with a fixed moving structure which drives the inner key sleeve to move horizontally and locks the horizontal position after the charging gun is matched with the charging socket in an inserted mode; according to the invention, by arranging the compound mechanism, the test links such as plugging, axial tension holding and on-load unlocking can be integrated, the comprehensive reliability of the charging interface can be more truly and strictly checked, and the test platform can adapt to charging interfaces of different models and different dimensions, so that the universality and flexibility of the test platform are improved.

Description

Technical Field

[0001] This invention relates to the field of cable joint testing technology, specifically to a testing device and method for cable joints in new energy vehicles. Background Technology

[0002] "Cable connector" is a general term referring to coupling components in the electrical system of new energy vehicles, specifically including charging guns and charging sockets. With the rapid development of the new energy vehicle industry, the reliability of its high-voltage electrical system, especially the durability and safety of the charging gun and charging socket as key nodes of energy transmission, is crucial. The charging interface needs to undergo frequent plugging and unplugging operations throughout the vehicle's entire life cycle and is exposed to complex conditions such as vibration, temperature cycling, and possible non-standard operations by users (such as pulling the cable while it is live). Therefore, conducting scientific, rigorous, and efficient reliability testing on the charging interface is a prerequisite for ensuring vehicle electrical safety and user experience.

[0003] Chinese Patent (Announcement No.: CN118150151A) describes a solution that includes a movable seat with a limit module that is elastically slidably set; a limit track set on the upper mold limit part and used to limit the locking button on the electric gun; and a control component for controlling the pressed state of the locking button. This new energy charging pile charging gun life testing device simultaneously performs insertion / removal testing and locking button pressing testing, effectively improving the safety, reliability, long-term operational stability of the charging equipment, as well as the reliability and comprehensiveness of the evaluation results. During the testing process, only continuous feeding of the movable seat is needed to automatically complete the initial insertion of the electric gun to the connection testing seat, pressing the locking button, complete insertion of the electric gun to the connection testing seat, releasing the locking button, and pushing back the upper mold limit part, simultaneously completing the insertion / removal testing and pressing testing.

[0004] The above solution has certain limitations: 1. Lack of Mechanical Self-Locking Stability Assessment: The locking mechanism of current mainstream charging connectors relies on the linear mechanical engagement between the elastic pressure tongue in the charging gun socket and the tongue groove in the socket. The resistance to axial separation (i.e., holding force) in the locked state is a key indicator for assessing connection reliability. The testing device in the aforementioned patent relies on an elastic limiting component to apply a continuous pre-tightening force to the charging gun during insertion. This design interferes with the natural engagement state of the connector without external force assistance, making it difficult to accurately measure the static holding force and tensile strength under purely mechanical self-locking conditions. This weakens the effectiveness of the test results in evaluating the locking stability of actual products.

[0005] 2. Insufficient test adaptability and fault tolerance: The pressing stroke and timing of the locking button in the above patent are precisely controlled by a preset fixed geometric trajectory (such as the reset slide section). This rigid design places stringent requirements on the positioning and installation accuracy of the charging gun on the fixture. At the same time, due to the lack of a position adaptive adjustment mechanism, it is difficult to adapt to cable connectors of different models, sizes, or manufacturing tolerances, which restricts the versatility and flexibility of the test platform.

[0006] Therefore, a testing device and testing method for cable connectors of new energy vehicles are proposed. Summary of the Invention

[0007] The purpose of this invention is to provide a testing device and method for cable connectors of new energy vehicles, which has the advantages of integrating insertion and extraction, axial tensile force retention, and load unlocking testing, and solves the problem of difficulty in accurately measuring static holding force and tensile strength under self-locking conditions.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a testing device for a new energy vehicle cable connector, comprising a base for supporting a charging socket and a charging gun, the charging gun being provided with a pressure tongue block and a spring button for controlling the retraction of the pressure tongue block, the charging socket being provided with a tongue groove for engaging with the pressure tongue block, and the base being provided with a composite mechanism for driving the charging gun and the charging socket to repeatedly insert and remove each other and applying an axial pulling force to the charging gun during engagement; The composite mechanism includes a spline shaft fixedly connected to the base, an inner key sleeve slidably sleeved on the spline shaft, an anchor seat fixedly connected to the inner key sleeve, an outer frame fixedly connected below the anchor seat, an inner bracket for fixing and supporting the charging gun on the outer frame, and a fixed-movement structure on the base that drives the inner key sleeve to move horizontally and locks the horizontal position after the charging gun and the charging socket are plugged in and engaged. The charging socket is fixedly connected to the base, and the outer frame is provided with a tensioning structure that applies a quantitative axial tensile force to the charging gun when the charging socket and the charging gun are in a locked state. The outer frame is also provided with a release structure that allows the charging socket and charging gun to be released by pressing a spring button after a quantitative pulling force is applied.

[0009] Preferably, the fixed displacement structure includes a positioning seat fixedly connected to the base, a central shaft that is driven by a motor and can rotate freely in the vertical direction on the positioning seat, an end plate seat on the side of the positioning seat facing the spline shaft, the central shaft is fixedly rotated on the end plate seat and coaxially fixed with a lateral worm gear, the lateral worm gear is meshed with multiple sets of lateral worm wheels, and the multiple sets of lateral worm wheels are all fixedly rotated on the end plate seat. The end plate seat rotates on a fixed axis on a positioning seat, and the positioning seat is provided with an internal pressure component that restricts the rotation of the end plate seat; A fixed pendulum rod is coaxially fixed on the lateral worm gear. A movable pendulum rod is rotatably mounted on the end of the fixed pendulum rod away from the lateral worm gear. A corresponding ring is rotatably mounted on the inner key sleeve. The end of the movable pendulum rod away from the fixed pendulum rod is rotatably mounted on the corresponding ring.

[0010] Preferably, the internal pressure assembly includes multiple sets of internal chambers formed on the positioning seat, and internal resistance blocks are slidably connected to the upper part of each set of internal chambers, with the internal resistance blocks in sliding contact with the end plate seat; The inner cavity is also provided with a retaining spring, and the two ends of the retaining spring are fixedly connected to the inner resistance block and the positioning seat, respectively. The supporting spring is always in a compressed state.

[0011] Preferably, the gear-pull structure includes a gear that rotates freely in the horizontal direction, the gear rotating on a fixed axis on an outer frame, the gear meshing with a rack, and a rectangular groove provided on the outer frame for sliding connection of the rack. The outer frame is provided with a positioning plate, the outer peripheral surface of the positioning plate is in sliding contact with the inner wall of the outer frame, the positioning plate is fixedly connected to the rack, and a positioning column is fixedly connected to the side of the positioning plate facing the inner frame. A force-applying spring is sleeved on the outer peripheral surface of the positioning column, and the two ends of the force-applying spring are fixedly connected to the positioning plate and the inner frame respectively. The outer frame is equipped with a movement stop component that limits the horizontal movement distance of the rack and the coordinating plate.

[0012] Preferably, the moving component includes two sets of lateral single teeth slidably connected to the rectangular groove, the two sets of lateral single teeth being located at the horizontal ends of the rack respectively, and both sets of lateral single teeth being meshed with the gear. A guide post slides through the edge-oriented single tooth, and the end of the guide post away from the edge-oriented single tooth is fixedly connected to the rack. A return spring is sleeved on the outer circumferential surface of the guide post, and the two ends of the return spring are fixedly connected to the rack and the edge-oriented single tooth, respectively.

[0013] Preferably, the pull structure further includes a central worm gear sleeved on the inner key sleeve, the central worm gear being coaxially fixed with the corresponding ring, and the central worm gear being meshed with a driven worm wheel. A U-shaped frame plate is fixedly connected to the outer frame, the driven worm wheel is rotatably mounted on the U-shaped frame plate, and a threaded rod is coaxially fixed on the driven worm wheel, the threaded rod being coaxially fixed with the gear.

[0014] Preferably, the release structure includes a cone-shaped seat that can move freely up and down in the vertical direction as the threaded rod rotates, a directional column is fixedly connected to the U-shaped frame plate, the cone-shaped seat is slidably sleeved on the directional column, the threaded rod is threadedly connected to an internal threaded cylinder, and the cone-shaped seat rotates on the internal threaded cylinder on a fixed axis. The cone-shaped seat is provided with a crank and a groove for the crank to slide through. The end of the crank away from the cone-shaped seat slides through the anchor seat and is fixedly connected to a rubber block that is in pressure contact with the spring button.

[0015] Preferably, the cone-shaped seat is provided with an inner wedge plate and a groove two for sliding connection of the inner wedge plate. A relief spring is provided in the groove two. The two ends of the relief spring are fixedly connected to the cone-shaped seat and the inner wedge plate respectively. The internal threaded cylinder is provided with a wedge-shaped groove for wedging with the inner wedge plate at the position corresponding to the inner wedge plate. The inner wedge plate is fixedly connected to a limit pin on one side facing the crank, and the crank is provided with a V-shaped groove for the limit pin to slide.

[0016] Preferably, a testing method for cable connectors in new energy vehicles, applied to a testing device for cable connectors in new energy vehicles, includes the following steps: S1. Initialization and benchmark testing: Fix the charging gun under test on the inner frame, fix the charging socket under test on the base, and drive the charging socket and charging gun to maintain initial alignment. Perform benchmark testing and record the initial parameters, including locking sound characteristics, contact resistance, HVIL circuit resistance and insulation resistance, as benchmark data for performance degradation. S2, Single insertion / removal test: S21, Adaptive plug-in cooperation: The charging gun is driven to move horizontally adaptively along the direction of the charging socket through a fixed displacement structure, and the locking sound is captured by an acoustic sensor; S22, Axial Holding Force Test: When the charging socket and charging gun are in a locked state, a controllable, continuous and gradually increasing axial force is applied to the charging gun through the pull structure until the axial force reaches the set value. S23. Load unlocking: While maintaining axial tension, release the structural pressing button to cause the pressing tongue block to disengage from the tongue groove, verify whether the tongue groove has successfully retracted, and simultaneously confirm whether the HVIL circuit is immediately disconnected at this moment of physical unlocking. S24, Separation and Reset: After both the charging socket and the charging gun are unlocked, the translation component carries the charging gun back to the initial position; S3. Loop Execution and Process Monitoring: Repeat step S2 to perform a set number of loop tests, and monitor and record the process parameters of each loop in real time. S4. Periodic electrical performance sampling: After completing the set cycle interval, pause the plugging and unplugging test process and perform electrical tests on the charging socket and charging gun, including contact resistance test, HVIL circuit test and insulation resistance test. S5. Failure Judgment and Report Generation: Based on the data from the cyclic plug-in test and electrical test, the test product is judged to have failed when both the charging socket and the charging gun fail to lock, cannot be unlocked, or have abnormal electrical parameters. A comprehensive test report is generated, including process parameter curves, electrical performance degradation diagrams, failure cycle points, and final judgment conclusions.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. By setting up a composite mechanism, this invention can integrate testing links such as insertion and removal, axial tensile force holding, and load unlocking, which can more realistically and rigorously assess the comprehensive reliability of the charging interface. It can be adapted to charging interfaces of different models and sizes, thereby improving the versatility and flexibility of the testing platform.

[0018] 2. This invention, by setting up a tensioning structure, precisely controls the displacement of the co-position plate through gears and racks, thereby precisely controlling the deformation of the force-applying spring. This enables a quantitative and linear increase in the axial tension applied to the charging gun. It can measure the performance of the locking mechanism before reaching the critical failure tension, and can set and repeat different tension thresholds for testing to enhance data comparability. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the charging socket and charging gun structure of the present invention; Figure 3 This is a schematic diagram of the component containing the colocation plate of the present invention; Figure 4 This is a schematic diagram of the component containing the anchorage of the present invention; Figure 5 For the present invention Figure 4 Enlarged view of point A in the middle; Figure 6 This is a schematic diagram of the component containing the positioning seat of the present invention; Figure 7 This is a schematic diagram of the component containing the internal resistance block of the present invention; Figure 8 This is a schematic diagram of the component containing the corresponding ring of the present invention; Figure 9 This is a schematic diagram of the component containing the cone-shaped seat of the present invention; Figure 10 This is a flowchart illustrating the steps of a testing method for cable connectors in new energy vehicles according to the present invention.

[0020] In the diagram: 1. Charging socket; 101. Tongue groove; 2. Charging gun; 201. Tongue pressing block; 202. Spring button; 3. Base; 4. Positioning seat; 5. End plate seat; 6. Central shaft; 7. Side worm gear; 8. Side worm wheel; 9. Holding spring; 10. Internal resistance block; 11. Fixed swing rod; 12. Moving swing rod; 13. Splined shaft; 14. Internal key sleeve; 15. Corresponding ring; 16. Anchor seat; 17. Outer frame; 18. Inner bracket; 19. Corresponding plate; 20. Corresponding post; 21. Force-applying spring; 22. Central worm gear; 23. Driven worm wheel; 24. U-shaped frame plate; 25. Threaded rod; 26. Gear; 27. Rack; 28. Side-direction single tooth; 29. ​​Guide post; 30. Return spring; 31. Conical seat; 32. Internal threaded cylinder; 33. Internal wedge plate; 34. Limiting pin; 35. Crank rod; 36. V-shaped groove; 37. Relief spring; 38. Directional post. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0022] Please see Figures 1 to 10 The present invention provides a technical solution: a testing device for a new energy vehicle cable connector, including a base 3 for supporting a charging socket 1 and a charging gun 2, the charging gun 2 is provided with a pressure tongue block 201 and a spring button 202 for controlling the retraction of the pressure tongue block 201, the charging socket 1 is provided with a tongue groove 101 for engaging with the pressure tongue block 201, and the base 3 is provided with a composite mechanism that drives the charging gun 2 and the charging socket 1 to repeatedly insert and remove each other and applies an axial pulling force to the charging gun 2 during engagement; The composite mechanism includes a spline shaft 13 fixedly connected to the base 3, an inner key sleeve 14 slidably sleeved on the spline shaft 13, an anchor 16 fixedly connected to the inner key sleeve 14, an outer frame 17 fixedly connected below the anchor 16, an inner bracket 18 for fixing and supporting the charging gun 2 on the outer frame 17, and a fixed displacement structure on the base 3 that drives the inner key sleeve 14 to move horizontally and locks the horizontal position after the charging gun 2 is plugged into the charging socket 1. The charging socket 1 is fixedly connected to the base 3, and the outer frame 17 is provided with a tensioning structure that applies a quantitative axial tension to the charging gun 2 when the charging socket 1 and the charging gun 2 are in a locked state. The outer frame 17 is also provided with a release structure that allows the charging socket 1 and the charging gun 2 to be released from their locked state by pressing the spring button 202 after a quantitative pulling force is applied.

[0023] like Figures 1-3 As shown, when performing performance testing on the charging socket 1 and the charging gun 2 used in conjunction with it on the car, the charging gun 2 to be tested is first fixedly installed on the inner bracket 18. Anchors can be provided on the inner bracket 18 to facilitate the fixing of charging guns 2 of different sizes or specifications. Subsequently, the charging socket 1 is installed on the base 3 through the external bracket, and the electrical connection point of the charging socket 1 and the charging gun 2 are aligned.

[0024] At the same time, the inner key sleeve 14 is driven to move horizontally along the laying direction of the spline shaft 13 by the fixed displacement structure, which in turn drives the anchor seat 16 and the outer frame 17 fixed on it to move horizontally synchronously. During this process, the inner frame 18 carries the charging gun 2 and moves horizontally synchronously with the outer frame 17, thereby gradually reducing the horizontal distance between the charging socket 1 and the charging gun 2 until the two are locked together.

[0025] When the charging socket 1 and the charging gun 2 are in the locked state, that is, when the pressure block 201 enters the tongue groove 101, the inner frame 18, the outer frame 17, the anchor seat 16 and the inner key sleeve 14 will no longer be able to move horizontally. Thereafter, the continuous operation of the fixed displacement structure will drive the matching pull structure to operate. The matching pull structure can apply a certain horizontal pulling force to the inner frame 18 through the elastic element, thereby simulating the external pulling force encountered by the charging gun 2 during use. By measuring the stability of the pressure block 201 and the tongue groove 101 under axial tension, the tensile strength and reliability of the charging socket 1 and the charging gun 2 can be evaluated.

[0026] Simultaneously, after applying a fixed axial tension to the central worm gear 22, the release structure press button 202 causes the pressure block 201 to retract a certain distance, thereby allowing the pressure block 201 to disengage from the tongue groove 101. In actual use, the engagement process between the pressure block 201 and the tongue groove 101 is achieved through the cooperation of mechanical parts. This part is an existing device and a technical means well known to those skilled in the art, so it is not illustrated. During the cooperation process, there are specific sound characteristics. By detecting these sound characteristics, it is possible to determine whether the two can operate normally, and to a certain extent, the change in these sound characteristics can be used to detect the service life of the two.

[0027] When the pressure block 201 disengages from the tongue groove 101, the fixed displacement structure causes the inner key sleeve 14 to carry the charging gun 2 away from the charging socket 1, thereby driving the charging gun 2 back to its initial horizontal position. In the actual testing process, the repeated insertion and removal of the charging socket 1 and the charging gun 2 causes their terminals to come into contact and rub against each other, resulting in wear of the plating. Therefore, after a set number of insertions and removals, the electrical performance of both needs to be tested, including contact resistance testing, HVIL circuit testing, and insulation resistance testing, to evaluate whether they can maintain a low-resistance, high-reliability connection after repeated insertions and removals.

[0028] In one preferred embodiment, the fixed displacement structure includes a positioning seat 4 fixedly connected to the base 3. The positioning seat 4 is provided with a central shaft 6 that is driven by a motor and can rotate freely in the vertical direction. The positioning seat 4 is provided with an end plate seat 5 on the side facing the spline shaft 13. The central shaft 6 is fixedly rotated on the end plate seat 5 and coaxially fixed with a lateral worm gear 7. The lateral worm gear 7 is meshed with multiple sets of lateral worm wheels 8, and the multiple sets of lateral worm wheels 8 are all fixedly rotated on the end plate seat 5. The end plate seat 5 is fixedly rotated on the positioning seat 4. The positioning seat 4 is provided with an internal pressure component that restricts the rotation of the end plate seat 5. A fixed swing rod 11 is coaxially fixed on the lateral worm gear 8. A movable swing rod 12 is fixedly rotated on the end of the fixed swing rod 11 away from the lateral worm gear 8. A corresponding ring 15 is fixedly rotated on the inner key sleeve 14. The end of the movable swing rod 12 away from the fixed swing rod 11 is fixedly rotated on the corresponding ring 15.

[0029] The internal pressure assembly includes multiple sets of internal chambers opened on the positioning seat 4. Each set of internal chambers is slidably connected to an internal resistance block 10. The internal resistance block 10 is in sliding contact with the end plate seat 5. The internal chamber is also provided with a retaining spring 9. The two ends of the retaining spring 9 are respectively fixedly connected to the internal resistance block 10 and the positioning seat 4. The retaining spring 9 is always in a compressed state.

[0030] like Figure 1 , Figure 6 and Figure 7 As shown, the central shaft 6 is driven to rotate in the vertical direction by a motor fixed on the positioning seat 4, which in turn drives the lateral worm gear 7, which is coaxially fixed with the central shaft 6, to rotate synchronously. Under the drive of the internal pressure component, when the central shaft 6 initially rotates, the end plate seat 5 will not rotate with the central shaft 6.

[0031] At the same time, when the lateral worm 7 rotates, it can drive the multiple sets of lateral worm wheels 8 meshing with it to rotate. When the lateral worm wheel 8 rotates, it drives the fixed pendulum rod 11 fixed on the same axis to swing. A movable pendulum rod 12 with free deflection is provided between the fixed pendulum rod 11 and the corresponding ring 15. When the fixed pendulum rod 11 swings with the lateral worm wheel 8, it can change the included angle between the fixed pendulum rod 11 and the movable pendulum rod 12 to cause the corresponding ring 15 and the inner key sleeve 14 to move along the horizontal laying direction of the spline shaft 13 until the charging gun 2 and the charging socket 1 are in a locked state.

[0032] When the charging socket 1 and the charging gun 2 are in the locked state, the inner key sleeve 14 will be unable to continue horizontal movement due to the obstruction of the charging socket 1. After that, when the central shaft 6 continues to rotate, it will cause the end plate seat 5 to resist the rotational resistance it receives. The rotational resistance mainly comes from the positive frictional resistance applied to the end plate seat 5 by the inner resistance block 10 due to the compression deformation of the supporting spring 9. At this time, the central shaft 6 drives the lateral worm 7, the lateral worm wheel 8 and the end plate seat 5 to rotate synchronously on the positioning seat 4, and further drives the corresponding ring 15 to rotate on the inner key sleeve 14 through the fixed swing rod 11 and the moving swing rod 12. The rotation process of the corresponding ring 15 then causes the pulling structure to run.

[0033] Based on the fixed-movement structure embodiment, the pull structure includes a gear 26 that rotates freely in the horizontal direction. The gear 26 rotates on the outer frame 17 with a fixed axis. The gear 26 is meshed with a rack 27. A rectangular groove is provided on the outer frame 17 for the rack 27 to slide. The outer frame 17 is provided with a positioning plate 19, the outer peripheral surface of the positioning plate 19 is in sliding contact with the inner wall of the outer frame 17, the positioning plate 19 is fixedly connected to the rack 27, the side of the positioning plate 19 facing the inner frame 18 is fixedly connected with a positioning post 20, the outer peripheral surface of the positioning post 20 is fitted with a force spring 21, the two ends of the force spring 21 are fixedly connected to the positioning plate 19 and the inner frame 18 respectively, and the outer frame 17 is provided with a movement stop assembly to limit the horizontal movement distance of the rack 27 and the positioning plate 19.

[0034] The displacement assembly includes two sets of lateral single teeth 28 slidably connected to a rectangular groove. The two sets of lateral single teeth 28 are located at the horizontal ends of the rack 27, and both sets of lateral single teeth 28 are meshed with gears 26. A guide post 29 slidably passes through the lateral single teeth 28. One end of the guide post 29 away from the lateral single teeth 28 is fixedly connected to the rack 27. A return spring 30 is sleeved on the outer circumferential surface of the guide post 29. The two ends of the return spring 30 are fixedly connected to the rack 27 and the lateral single teeth 28, respectively.

[0035] The pull structure also includes a central worm 22 sleeved on the inner key sleeve 14. The central worm 22 is coaxially fixed with the corresponding ring 15, and the central worm 22 is meshed with a driven worm wheel 23. A U-shaped frame plate 24 is fixedly connected to the outer frame 17. The driven worm wheel 23 rotates on the U-shaped frame plate 24 with a fixed axis, and a threaded rod 25 is coaxially fixed on the driven worm wheel 23. The threaded rod 25 is coaxially fixed with the gear 26.

[0036] like Figure 1 , Figure 4 , Figure 5 , Figure 6 , Figure 8 and Figure 9 As shown, when the charging socket 1 and the charging gun 2 are in the locked state, the subsequent rotation of the central shaft 6 will drive the corresponding ring 15 to rotate on the inner key sleeve 14, thereby causing the central worm 22, which is coaxially fixed with the corresponding ring 15, to rotate synchronously. The central worm 22 is meshed with the driven worm wheel 23, which in turn drives the driven worm wheel 23 and the threaded rod 25 and gear 26, which are coaxially fixed with the driven worm wheel 23, to rotate synchronously in the horizontal direction.

[0037] During this process, the rotation of gear 26 will drive rack 27 to slide on rectangular groove, thereby changing the horizontal position of the co-position plate 19 fixedly connected to rack 27, so as to cause co-position plate 19 to move away from inner bracket 18, and drive co-position post 20 between the two to elongate and deform. The elongation and deformation of co-position post 20 gradually increases the axial tension on charging gun 2. At the same time, co-position plate 19 is provided with co-position post 20, so when inner key sleeve 14 moves horizontally, it can push inner bracket 18 through co-position post 20, so as to cause charging gun 2 to move synchronously toward charging socket 1.

[0038] Meanwhile, as gear 26 continues to rotate, a set of side-oriented single teeth 28 provided at the end of rack 27 meshes with gear 26. During the rotation of gear 26, the side-oriented single teeth 28 can be moved toward the rack 27. Under the action of the elastic potential energy of return spring 30, the side-oriented single teeth 28 are repeatedly bounced on rack 27 to meet the subsequent rotation requirements of gear 26. When gear 26 rotates in the opposite direction, it can mesh with rack 27 again through its own meshing relationship with side-oriented single teeth 28, thereby driving the co-position plate 19 to return to the initial horizontal position. The return spring 30 can be replaced to apply different degrees of axial tension to charging gun 2.

[0039] It should be noted that, in actual use, a buffer can be set between the co-position plate 19 and the inner frame 18 to prevent the inner frame 18 from bouncing excessively on the outer frame 17. At the same time, the stability and shock resistance of the internal parts of the charging gun 2 can be tested by restoring the bouncing process of the inner frame 18 and the charging gun 2 in the horizontal direction caused by the deformation through the force spring 21.

[0040] Based on the embodiment of the pull structure, the release structure includes a cone-shaped seat 31 that can freely rise and fall in the vertical direction as the threaded rod 25 rotates. A directional column 38 is fixedly connected to the U-shaped frame plate 24. The cone-shaped seat 31 is slidably sleeved on the directional column 38. The threaded rod 25 is threadedly connected to an internal threaded cylinder 32. The cone-shaped seat 31 rotates on the internal threaded cylinder 32 with a fixed axis. The cone-shaped seat 31 is provided with a crank 35 and a groove for the crank 35 to slide through. The end of the crank 35 away from the cone-shaped seat 31 slides through the anchor seat 16, and a rubber block that is pressed and contacted with the spring button 202 is fixedly connected to the crank 35.

[0041] The conical seat 31 is provided with an inner wedge plate 33 and a groove 2 for sliding connection of the inner wedge plate 33. A relief spring 37 is provided in the groove 2. The two ends of the relief spring 37 are fixedly connected to the conical seat 31 and the inner wedge plate 33 respectively. The internal threaded cylinder 32 is provided with a wedge-shaped groove for wedging with the inner wedge plate 33 at the position corresponding to the inner wedge plate 33. A limit pin 34 is fixedly connected to the side of the inner wedge plate 33 facing the crank 35. A V-shaped groove 36 is provided on the crank 35 for sliding connection of the limit pin 34.

[0042] like Figure 1 , Figure 8 and Figure 9 As shown, when the threaded rod 25 is rotating, in the initial state, since the inner wedge plate 33 is in the wedge groove and the cone angle seat 31 cannot rotate around the threaded rod 25 as the center under the restriction of the directional column 38, the rotation process of the threaded rod 25 will change the horizontal height of the cone angle seat 31 and the crank 35 set on it through the inner threaded cylinder 32 until the rubber block set at the end of the crank 35 squeezes the spring button 202 and causes the pressure tongue block 201 to retract. At this time, the crank 35 can no longer move downward.

[0043] Meanwhile, as the threaded rod 25 continues to rotate, the cone seat 31 continues to move downward, which in turn causes a relative displacement between the internal threaded cylinder 32 and the crank 35, thereby causing the limiting pin 34 to slide on the V-shaped groove 36. At this time, the inner wedge plate 33 slides in the groove until the inner wedge plate 33 disengages from the wedge groove. After that, when the threaded rod 25 rotates, since the internal threaded cylinder 32 will no longer be restricted by the inner wedge plate 33, the central worm 22 will rotate with the threaded rod 25 without changing the horizontal height of the cone seat 31 and the crank 35.

[0044] It should be noted that during the actual testing process, the forward rotation of the central shaft 6 first causes the inner key sleeve 14 to slide on the spline shaft 13, thereby driving the charging gun 2 to move towards the charging socket 1 until the two are locked together. After that, the rotation of the central shaft 6 will drive the corresponding ring 15 to rotate, and drive the threaded rod 25 and gear 26 to rotate, thereby causing the crank 35 to move downward and the force spring 21 to gradually elongate and deform, so as to gradually increase the axial tension applied to the charging gun 2. After the axial tension reaches the set maximum value, the crank 35 continues to move downward and presses the spring button 202, thereby unlocking the charging socket 1 and the charging gun 2. Subsequently, the central shaft 6 can be driven to rotate in the opposite direction, causing the inner key sleeve 14 to move horizontally to the initial position. After the inner key sleeve 14 is in the initial position, it can no longer move horizontally, thereby causing the corresponding ring 15 to rotate in the opposite direction, so as to realize the reset process of each component.

[0045] A testing method for cable connectors in new energy vehicles, applied to a testing device for cable connectors in new energy vehicles, includes the following steps: S1. Initialization and benchmark test: Fix the charging gun 2 under test on the inner bracket 18, fix the charging socket 1 under test on the base 3, and drive the charging socket 1 and the charging gun 2 to maintain initial alignment. Perform benchmark test and record the initial parameters, including locking sound characteristics, contact resistance, HVIL circuit resistance and insulation resistance, as benchmark data for performance degradation. S2, Single insertion / removal test: S21, Adaptive plugging and mating: The charging gun 2 is driven to move adaptively horizontally along the direction of the charging socket 1 by a fixed displacement structure, and the locking sound is captured by an acoustic sensor; S22, Axial holding force test: When the charging socket 1 and the charging gun 2 are in the locked state, a controllable, continuous and gradually increasing axial tension is applied to the charging gun 2 through the pull structure until the axial tension reaches the set value. S23, Load unlocking: While maintaining axial tension, release the structural pressing button 202 to cause the pressing block 201 to disengage from the tongue groove 101, verify whether the tongue groove 101 has successfully retracted, and simultaneously confirm whether the HVIL circuit is immediately disconnected at this moment of physical unlocking. S24, Separation and Reset: After both the charging socket 1 and the charging gun 2 are unlocked, the translation component carries the charging gun 2 back to the initial position; S3. Loop Execution and Process Monitoring: Repeat step S2 to perform a set number of loop tests, and monitor and record the process parameters of each loop in real time. S4. Periodic electrical performance sampling: After completing the set cycle interval, pause the plugging and unplugging test process and perform electrical tests on the charging socket 1 and charging gun 2, including contact resistance test, HVIL circuit test and insulation resistance test. S5. Failure Judgment and Report Generation: Based on the cyclic plug-in test and electrical test data, the test product is judged to have failed when both charging socket 1 and charging gun 2 fail to lock, cannot be unlocked, or have abnormal electrical parameters. A comprehensive test report is generated, including process parameter curves, electrical performance degradation diagrams, failure cycle points, and final judgment conclusions.

[0046] like Figure 10 As shown, to assess the impact of mechanical wear on electrical performance, an in-situ, non-disassembly sampling method can be used. Through a built-in multiplexed relay matrix or a retractable test probe, the electrical terminals of the charging socket 1 and charging gun 2 under test are automatically connected to the testing instrument. Specifically, the following steps are performed sequentially: Contact resistance test: The four-wire Kelvin method is used to apply a standard test current to each pair of high-voltage terminals and accurately measure the change in their resistance value. HVIL loop test: Measure the resistance of the entire HVIL loop to ensure that it remains a low-resistance, reliable connection; Insulation resistance test: After short-circuiting all high-voltage terminals, apply a specified DC high voltage between them and the grounding terminal, and measure the insulation resistance.

[0047] In actual use, electrical test results are strictly correlated with the corresponding number of cycles to form performance degradation trend data.

[0048] At the same time, a final determination is made based on preset thresholds, and the failure criteria include, but are not limited to: Mechanical failure: The tongue block 201 and the tongue groove 101 disengage when not unlocked or when the pulling force is insufficient; the spring button 202 cannot be pressed down or the locking tongue cannot retract.

[0049] Electrical failure: Contact resistance increases by more than 50%; insulation resistance is lower than the specified value; HVIL circuit resistance is abnormal or the on / off state is asynchronous.

[0050] Functional failure: The on / off state of the HVIL signal is out of sync with the mechanical action for more than the allowable time.

[0051] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A testing device for a new energy vehicle cable connector, comprising a base (3) for supporting a charging socket (1) and a charging gun (2), wherein the charging gun (2) is provided with a pressure tongue block (201) and a spring button (202) for controlling the retraction of the pressure tongue block (201), and the charging socket (1) is provided with a tongue groove (101) for engaging with the pressure tongue block (201), characterized in that: The base (3) is provided with a composite mechanism that drives the charging gun (2) to repeatedly plug and unplug with the charging socket (1) and applies axial tension to the charging gun (2) during the plugging and unplugging process; The composite mechanism includes a spline shaft (13) fixedly connected to the base (3), an inner key sleeve (14) slidably sleeved on the spline shaft (13), an anchor seat (16) fixedly connected on the inner key sleeve (14), an outer frame (17) fixedly connected below the anchor seat (16), an inner bracket (18) for fixing and supporting the charging gun (2) on the outer frame (17), and a fixed displacement structure on the base (3) for driving the inner key sleeve (14) to move horizontally and locking the horizontal position after the charging gun (2) is plugged into the charging socket (1). The charging socket (1) is fixedly connected to the base (3), and the outer frame (17) is provided with a tensioning structure that applies a quantitative axial tension to the charging gun (2) when the charging socket (1) and the charging gun (2) are in a locked state; The outer frame (17) is also provided with a release structure that allows the user to press the spring button (202) after applying a quantitative pulling force to release the locking state of the charging socket (1) and the charging gun (2).

2. The testing device for a new energy vehicle cable connector according to claim 1, characterized in that: The fixed displacement structure includes a positioning seat (4) fixedly connected to the base (3). The positioning seat (4) is provided with a central shaft (6) that is driven by a motor and can rotate freely in the vertical direction. The positioning seat (4) is provided with an end plate seat (5) on the side facing the spline shaft (13). The central shaft (6) rotates on the end plate seat (5) and is coaxially fixed with a lateral worm gear (7). The lateral worm gear (7) is meshed with multiple sets of lateral worm wheels (8). The multiple sets of lateral worm wheels (8) all rotate on the end plate seat (5) on a fixed axis. The end plate seat (5) rotates on a fixed axis on a positioning seat (4), and the positioning seat (4) is provided with an internal pressure component that restricts the rotation of the end plate seat (5); A fixed pendulum rod (11) is coaxially fixed on the lateral worm gear (8). A movable pendulum rod (12) is fixedly rotated at the end of the fixed pendulum rod (11) away from the lateral worm gear (8). A corresponding ring (15) is fixedly rotated on the inner key sleeve (14). The end of the movable pendulum rod (12) away from the fixed pendulum rod (11) is fixedly rotated on the corresponding ring (15).

3. The testing device for a new energy vehicle cable connector according to claim 2, characterized in that: The internal pressure assembly includes multiple sets of internal chambers opened on the positioning seat (4), and internal resistance blocks (10) are slidably connected to the upper part of each set of internal chambers. The internal resistance blocks (10) and the end plate seat (5) are in sliding contact. The inner cavity is also provided with a retaining spring (9), and the two ends of the retaining spring (9) are fixedly connected to the inner resistance block (10) and the positioning seat (4) respectively; The supporting spring (9) is always in a compressed state.

4. The testing device for a new energy vehicle cable connector according to claim 2, characterized in that: The pull structure includes a gear (26) that rotates freely in the horizontal direction. The gear (26) rotates on the outer frame (17) with a fixed axis. The gear (26) is meshed with a rack (27). The outer frame (17) has a rectangular groove for sliding connection of the rack (27). The outer frame (17) is provided with a coordinating plate (19), the outer peripheral surface of the coordinating plate (19) is in sliding contact with the inner wall of the outer frame (17), the coordinating plate (19) is fixedly connected to the rack (27), and a coordinating column (20) is fixedly connected to one side of the coordinating plate (19) facing the inner frame (18). A force-applying spring (21) is sleeved on the outer peripheral surface of the coordinating column (20), and the two ends of the force-applying spring (21) are fixedly connected to the coordinating plate (19) and the inner frame (18) respectively. The outer frame (17) is provided with a movement stop assembly that limits the horizontal movement distance of the rack (27) and the co-position plate (19).

5. The testing device for a new energy vehicle cable connector according to claim 4, characterized in that: The moving and stopping component includes two sets of lateral single teeth (28) slidably connected on a rectangular groove. The two sets of lateral single teeth (28) are located at the horizontal ends of the rack (27) respectively, and both sets of lateral single teeth (28) are meshed with the gear (26). A guide post (29) slides through the edge-oriented single tooth (28). The end of the guide post (29) away from the edge-oriented single tooth (28) is fixedly connected to the rack (27). A return spring (30) is sleeved on the outer circumferential surface of the guide post (29). The two ends of the return spring (30) are fixedly connected to the rack (27) and the edge-oriented single tooth (28), respectively.

6. The testing device for a new energy vehicle cable connector according to claim 4, characterized in that: The pull structure also includes a central worm (22) sleeved on the inner key sleeve (14), the central worm (22) and the corresponding ring (15) are coaxially fixed, and the central worm (22) is meshed with a driven worm wheel (23). A U-shaped frame plate (24) is fixedly connected to the outer frame (17), the driven worm wheel (23) rotates on the U-shaped frame plate (24) on a fixed axis, and a threaded rod (25) is coaxially fixed on the driven worm wheel (23), and the threaded rod (25) and the gear (26) are coaxially fixed.

7. The testing device for a new energy vehicle cable connector according to claim 6, characterized in that: The release structure includes a cone-shaped seat (31) that moves freely up and down in the vertical direction as the threaded rod (25) rotates. A directional column (38) is fixedly connected to the U-shaped frame plate (24). The cone-shaped seat (31) is slidably sleeved on the directional column (38). The threaded rod (25) is threadedly connected to an internal threaded cylinder (32). The cone-shaped seat (31) rotates on the internal threaded cylinder (32) with a fixed axis. The cone-shaped seat (31) is provided with a crank (35) and a groove for the crank (35) to slide through. The end of the crank (35) away from the cone-shaped seat (31) slides through the anchor seat (16), and a rubber block that is in pressure contact with the spring button (202) is fixedly connected to the crank (35).

8. The testing device for a new energy vehicle cable connector according to claim 7, characterized in that: The cone-shaped seat (31) is provided with an inner wedge plate (33) and a groove for sliding connection of the inner wedge plate (33). A relief spring (37) is provided in the groove. The two ends of the relief spring (37) are fixedly connected to the cone-shaped seat (31) and the inner wedge plate (33) respectively. The internal threaded cylinder (32) is provided with a wedge-shaped groove for wedge engagement with the inner wedge plate (33) at the position corresponding to the inner wedge plate (33). The inner wedge plate (33) is fixedly connected to a limiting pin (34) on one side facing the crank (35), and a V-shaped groove (36) is provided on the crank (35) for the limiting pin (34) to slide.

9. A test method for a new energy vehicle cable connector, applied to the test apparatus for a new energy vehicle cable connector as described in any one of claims 1-8, characterized in that, Includes the following steps: S1. Initialization and benchmark test: Fix the charging gun (2) under test on the inner frame (18), fix the charging socket (1) under test on the base (3), and drive the charging socket (1) and the charging gun (2) to maintain initial alignment. Perform benchmark test and record initial parameters, including locking sound characteristics, contact resistance, HVIL circuit resistance and insulation resistance, as benchmark data for performance degradation. S2, Single insertion / removal test: S21, Adaptive plug-in cooperation: The charging gun (2) is driven to move horizontally in the direction of the charging socket (1) by a fixed displacement structure, and the locking sound is captured by an acoustic sensor; S22, Axial holding force test: When the charging socket (1) and the charging gun (2) are in a locked state, a controllable, continuous and gradually increasing axial force is applied to the charging gun (2) through the pull structure until the axial force reaches the set value; S23, Load unlocking: While maintaining axial tension, release the structural pressing button (202) to cause the pressing block (201) to disengage from the tongue groove (101), verify whether the tongue groove (101) has successfully retracted, and simultaneously confirm whether the HVIL circuit is immediately disconnected at this moment of physical unlocking; S24, Separation and Reset: After the charging socket (1) and the charging gun (2) are unlocked, the translation component carries the charging gun (2) back to the initial position; S3. Loop Execution and Process Monitoring: Repeat step S2 to perform a set number of loop tests, and monitor and record the process parameters of each loop in real time. S4. Periodic electrical performance sampling: After completing the set cycle interval, pause the plugging and unplugging test process and perform electrical tests on the charging socket (1) and charging gun (2), including contact resistance test, HVIL circuit test and insulation resistance test. S5. Failure Judgment and Report Generation: Based on the cyclic plug-in test and electrical test data, the test product is judged to be faulty when the charging socket (1) and charging gun (2) fail to lock, cannot be unlocked, or have abnormal electrical parameters. A comprehensive test report is generated, including process parameter curves, electrical performance degradation diagrams, failure cycle points, and final judgment conclusions.

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