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UL 2594 Drive Over Tire Load Test System for EV Charging Connectors with PLC Control
The Vehicle Drive-Over Crushing Test System evaluates the mechanical resistance of electric vehicle plugs and connectors when subjected to accidental vehicle rolling. This advanced testing equipment simulates real-world driving conditions where connectors may be left on the ground and driven over, ensuring compliance with international safety standards for EV charging accessories.
Application & Test Purpose
This system verifies whether plugs or vehicle connectors can withstand damage caused by being driven over by vehicles, unless a cable management system prevents ground contact. The test ensures mechanical integrity under specified rolling forces and conditions, providing reliable safety validation for EV charging components.
Applicable Standards
IEC 62196-1:2022, Clause 33
IEC 62752:2016, Clause 9.34
UL 2594:2016, Clause 58
Test Principle
According to IEC and UL requirements, accessories wired with the manufacturer's minimum recommended conductor size are placed on a concrete surface in natural resting positions. A defined crushing force is applied using a standard automotive tire mounted on a steel rim and inflated to specified pressure. The tire rolls over test samples at controlled speeds, simulating real vehicle movement while securely fixing samples to prevent displacement.
Mechanical Structure & Design
The equipment features a fully enclosed protective structure constructed from cold-rolled steel plates with Teflon-coated surfaces for durability and corrosion resistance. The test base simulates concrete flooring to reproduce realistic installation conditions.
Heavy-duty linear guide rails supporting smooth roller movement
High-power motor combined with worm gear reducer for stable speed and torque output
Stainless steel and aluminum core components for long-term reliability
Integrated specimen fixing and sliding system for standard positioning requirements
Rolling Force & Drive System
Rolling load is generated by a counterweight system with adjustable force between 5000 N and 11,000 N. Counterweights are safely installed and removed using a cantilever crane for accurate load application. The system employs front-and-rear rolling drive mode with motor forward and reverse rotation, realistically simulating vehicle forward and reversing movements.
Tire Configuration & Inflation
5000 N Test Setup
Equipped with ST225/75R15 tire and matching wheel hub, including inflation interface and pressure gauge (ST225/75R15 selected as equivalent to P225/75R15).
11,000 N Test Setup
Equipped with dedicated high load-bearing tire and corresponding wheel hub.
Tire Inflation Pressure
IEC 62196: 220 ±10 kPa
UL 2594: 218 ±13 kPa (32 ±2 psi)
Recommended range: 205-230 kPa for both standards compatibility
Control & Operation
The system features an independent PLC control unit with 7-inch color touchscreen interface. Operators can choose between manual operation or fully automatic program-controlled testing, with precise parameter settings for rolling speed, stroke, and timing according to standard requirements.
Safety & Protection
Full protective fence to prevent accidental tire deviation
Leakage protection switch for electrical safety
Motor overload protection for stable long-term operation
Integrated braking mechanism to reduce impact and avoid rigid collisions
Technical Specifications
Parameter
Specification
Test Station
Single station
Control Method
PLC intelligent control with touchscreen operation
Operation Modes
Manual / Program-controlled
Rolling Stroke
0-2.0 m
Rolling Speed
(8 ±2) km/h, adjustable
Crushing Force Options
(5000 ±250) N, (11000 ±550) N, 4893 N (1100 lbf)
Power Supply
Three-phase AC 220V ±10%, 50/60 Hz
Installed Power
15 kW
Overall Dimensions
Approx. W4700 * D1300 * H3000 mm
Net Weight
Approx. 2400 kg
Product Images
Company Details
Bronze Gleitlager
,
Bronze Sleeve Bushings
and
Graphite Plugged Bushings
from Quality China Factory
Business Type:
Manufacturer
Total Annual:
800000-1500000
Employee Number:
30~50
Ecer Certification：
Verified Supplier
Sinuo is an innovation manufacturing company, specializing in the research and development and sales of laboratory construction and testing equipment for electrical appliances (covering the construction of energy efficiency and performance laboratories, as well as supplementary waterproof testing la... Sinuo is an innovation manufacturing company, specializing in the research and development and sales of laboratory construction and testing equipment for electrical appliances (covering the construction of energy efficiency and performance laboratories, as well as supplementary waterproof testing la...
