IEC 62196-1 EV Charging Connector Mechanical Load Test Apparatus

Test Sample Restriction: Charging connectors

Test Purpose: The charging connector shall be designed for easy insertion and removal of the charging gun, and shall prevent the gun from disengaging from the socket under normal operation. This test verifies whether the maximum force required to pull the charging gun out of the socket complies with specified standard limits.

Test Principle: Maximum pull-out force of socket: Apply the total force combined from standard specified weights (main weights, additional weights, hooks & clamping fixtures) and test plug assembly onto the test plug; the plug shall separate from the socket.

Operating Environment:Operating temperature: 5–35°C; Humidity: 30%–90%RH

Test Station	Single station
Gauge Configuration	Made of S136 steel. The pin gauge is manufactured to the minimum standard dimension with tolerance of +0.01 / 0 mm, center spacing tolerance ±0.05 mm, and surface roughness Ra 0.8 μm. Gauge is an optional accessory.
Test Items	7.11.8: Mechanical load test for charging connectors / Clause 14.1.6 (IEC 62196) 7.15.1.1: Locking device test / Clause 14.1.5 (IEC 62196) 7.17.1 d) e) f): Pull-out force test / Clause 14.1.5 (IEC 62196)
Main Technical Parameters of Charging Connector Mechanical Load Tester
Test Setup Diagram
Holding duration	60 seconds. Realized by hydraulic cylinder driving the tray to lift weights; time controlled manually.
Test cycles	4 times, one test at each 90° interval around the horizontal axis, manual operation.
Mechanical Load Weight Configuration	165N: 1 piece of 148.5N main weight + 1 piece of 16.5N additional weight 300N: 1 piece of 270N main weight + 1 piece of 30N additional weight 440N: 1 piece of 396N main weight + 1 piece of 44N additional weight 660N: 1 piece of 594N main weight + 1 piece of 66N additional weight 750N: 1 piece of 675N main weight + 1 piece of 75N additional weight Note: The weight of main weights includes the hook mass; target load force is achieved by stacking and combining different weights.
Main Technical Parameters of Latching Device Test
Test Setup Diagram
Test Holding Time	60 seconds. Weights are lifted and lowered by a hydraulic cylinder-driven tray; time is manually controlled.
Test Load Selection	Refer to Table 7
Test Requirement	The latching device shall be unlocked during testing.
Pull-out Force Weight Configuration	AC charging gun: 100N (90N + 10N) DC charging gun: 140N (126N + 14N)

• Full IEC 62196 Compliance
  Supports pull-out force, latching device & mechanical load tests; test data accepted by SGS/TÜV for global certification.
• All-in-One AC/DC Test Solution
  Single station covers both AC & DC charging guns with multi-range weights (100N–750N), cutting extra equipment costs & lab space.
• High Precision Optional S136 Gauge
  Anti-rust S136 steel pin gauge with tight tolerance ensures repeatable, accurate test results.
• Easy & Stable Manual Operation
  Hydraulic weight lifting with 60s adjustable holding time; 4-direction 90° horizontal testing, supported by operation manuals & remote video guidance.
• Wide Working Condition Adaptability
  Stable performance at 5–35℃, 30%–90%RH; no extra power needed for weight loading.