EV Charging Product Testing Capabilities

Testing In Action

Inside Workersbee’s EV Charging Test Lab

This video follows a product sample through selected checks in our lab—from insertion and cable bending to temperature monitoring, IP testing, terminal analysis, and test records.

Repeated Mechanical Use

Insertion and withdrawal cycles, together with cable bending, show how the connector interface, cable entry, and internal conductors respond to repeated movement.
Electrical Load and Temperature

Current loading, voltage drop, and multi-point temperature data show how the connector and cable assembly behave under electrical load.
Environment, Sealing, and Connections

Temperature and humidity exposure and IP tests check the enclosure and seals. Terminal cross-section analysis looks inside the crimped connection.

Testing Capability Overview

Key Testing Areas for EV Charging Products

E

Environmental Reliability Testing

Products and materials are exposed to temperature, humidity, salt spray, UV, and ozone conditions to examine their response to demanding storage and outdoor environments.

High / Low Temperature Humidity Salt Spray UV Aging Ozone Aging
M

Mechanical Durability Testing

Repeated mating, cable bending, torsion, pulling, vibration, and impact tests focus on interfaces, locking mechanisms, cable entries, and internal conductors.

Mating Cycles Cable Bending Torsion & Pulling Vibration Impact
E

Electrical Safety Testing

Insulation resistance, dielectric withstand, grounding, contact current, and protection checks are used to assess insulation integrity and protective functions.

Insulation Resistance Withstand Voltage Grounding Contact Current Protection Checks
T

Thermal and Electrical Performance

Current loading, temperature rise, and voltage drop tests examine how connectors, cables, and charging equipment behave under electrical load, with multiple channels used to record temperature and electrical data.

Current Loading Temperature Rise Voltage Drop Multi-Point Monitoring Functional Testing
I

Ingress Protection Testing

Dust and water tests examine seals, housings, interfaces, protective covers, and cable-entry points under defined IP test conditions.

IP5X IP6X IPX5 IPX7 Sealing Checks
M

Material and Terminal Analysis

Terminal cross-sections, crimp geometry, microhardness, surface wear, and material aging are examined at the component level.

Terminal Cross-Section Crimp Analysis Microhardness Abrasion Material Aging

Core Laboratory Equipment

Laboratory Equipment for EV Charging Product Testing

The equipment below represents part of our in-house test setup for EV connectors, portable EV chargers, charging cables, and related components.

Environmental Testing Equipment
1. Temperature and Humidity Chamber
2. Salt Spray Chamber
3. UV Aging Chamber
4. Ozone Aging Chamber
Mechanical Durability Equipment
1. Cable Bending and Flexing Testers
2. Connector Mating Cycle Tester
3. Pull, Twist, and Swing Life Tester
4. Vibration and Shock Test System
Electrical and Performance Equipment
1. Multi-Channel Data Acquisition System
2. Programmable DC Power Supply, up to 2000 A
3. Insulation, Withstand Voltage, and Grounding Testers
4. AC Charging Test System, up to 22 kW
Material and Terminal Analysis Equipment
1. Terminal Cross-Section Analyzer
2. Micro Vickers Hardness Tester
3. Abrasion Resistance Tester

Product Line Focus

Testing Focus by EV Charging Product Type

Test plans differ by product design, electrical rating, intended use, and applicable requirements. The main review areas for each product type are shown below.

EV Connectors

For AC and DC charging connectors, including CCS1, CCS2, NACS, Type 1, Type 2, and GB/T interfaces.

Temperature Rise Voltage Drop Mating Durability Locking & Interlock Insulation Resistance IP Protection

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Portable EV Chargers

For Mode 2 portable chargers integrating the control unit, protective functions, mains plug, charging cable, and vehicle connector.

Charging Function Control Pilot Leakage Protection Overtemperature Protection Grounding Insulation & Withstand Voltage

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EV Charging Cables

For charging cable assemblies and cable-to-connector connections exposed to repeated bending, pulling, twisting, and environmental conditions.

Cable Bending Dynamic Flexing Torsion & Pulling Conductor Continuity Jacket Wear Crimp Integrity

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EV Adapters

For adapter interfaces that combine different connector formats and require checks on fit, electrical continuity, temperature, and repeated use.

Interface Fit Electrical Continuity Temperature Rise Voltage Drop Mating Durability Insulation & Withstand Voltage

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Testing Workflow

Testing from Sample Review to Production Support

01
Product and Component Review

Product structure, terminals, cables, housings, seals, and other key parts are reviewed before the test plan is defined.
02
Test Plan and Sample Preparation

Test items and sample conditions are selected according to the product type, electrical rating, and project requirements.
03
Product Testing

Samples undergo the tests defined for the product and project, with results recorded for review.
04
Engineering Review

Test results are reviewed against the design, materials, connections, and intended use before the product moves forward.
05
Production Quality Checks

Applicable inspections and selected tests are used during production to check product consistency.
06
Test Records and Document Support

Selected test records, quality documents, and technical files may be provided according to the product and project.

STANDARDS & DOCUMENTATION

Standards and Documentation Support

Test items are selected according to the product type, target market, and applicable requirements. Available test records, quality documents, and technical files depend on the product and project scope.

Available Technical and Quality Documents

Depending on the product and project scope, available files may include:

Product specifications

Certification documents

Selected test records

Inspection and quality records

Technical drawings and supporting files

EV Charging Product Standards

IEC 62196 IEC 61851 IEC 62752 SAE J1772 UL 2251 UL 2594 GB/T 20234 GB/T 18487
Environmental, Mechanical, and Material Test References

IEC 60068 Series IEC 60529 ISO 16750 ISO 9227 EN 50620 ASTM G154 ASTM E384 USCAR-37

Need Test Records or Quality Documents for Your EV Charging Project?

Share your product type, target market, and project requirements. We’ll confirm which test records, certification documents, and quality files are available for review.

Request Available Documents