The charging system is the energy entry point of an electric vehicle and a hotspot for faults and customer complaints: burnt inlets, terminal temperature rise, insulation ageing and poor contact after repeated mating all affect the charging experience and safety directly.
Typical products
- On-board charger OBC (AC slow charging / DC fast charging)
- DC-DC converter
- Vehicle-side charge inlet and charging gun assembly
- PDU high-voltage distribution box
- Charging control box and charge management module
- On-board charging harness and high-voltage cable assemblies
Common test requirements
- EMC: conducted and radiated emission; the switching-frequency harmonics of the OBC are the focus.
- Temperature rise: temperature distribution at the inlet and terminals under rated load.
- Insulation resistance and dielectric withstand: clearance verification of the high-voltage circuit to the enclosure.
- Mating durability: mechanical mating cycles per the inlet standard.
- Salt mist corrosion: corrosion protection of contacts and plating.
- Ingress protection: exterior-mounted parts commonly require IP67.
- Vibration and mechanical shock: mechanical loads verified per mounting location.
Typical failure modes
- Burnt charge inlet and discoloured terminals.
- Poor crimping causing contact resistance drift and reduced charging power.
- Insulation resistance dropping in hot-humid environments.
- Contact wear and poor contact after repeated mating.
- Water ingress corrosion causing communication or earth failure.
Selection guidance
- Confirm the charging mode (AC slow / DC fast) and the inlet standard (GB/T, CCS, North American).
- Confirm the mounting location and the ingress requirement (exterior-mounted parts commonly IP67).
- Confirm the target-market regulation and the OEM specification.
- Confirm the load profile (rated current and duration).
Service notes
Our laboratory holds both CMA and CNAS accreditation, covers about 10,000 m2 and runs more than 500 sets of equipment. All testing is carried out in our own laboratories — nothing is subcontracted. Plant visits and on-site witnessed testing are welcome.
Scheduling follows the actual project pipeline. You can state your preferred lead time when you submit samples; we will confirm a feasible plan against current capacity and keep you updated at each milestone.
