The insertion and extraction force testing machine in the automotive electronics industry needs to be adaptedThe working conditions, high reliability requirements, and mass production efficiency of the in vehicle environmentThe three core pain points, compared to industries such as consumer electronics, have specific requirements in terms of environmental adaptation, mechanical performance, electrical synchronization testing, automation, and compliance. The following are based on industry standards (such asISO 6405TheUSCARTheGB/T 25085）Systematic analysis of practical application scenarios:

1、 Core special requirements: adapted to the in car environment

Automotive electronic components (such as connectors and buttons) need to withstand harsh working conditions such as high and low temperatures, vibration, and humidity. The testing machine needs to simulate these scenarios and ensure testing accuracy:

1. Adaptation to high and low temperature environments (core requirement)

temperature range: To be covered- 40℃(Severe cold in the north)~120℃(Engine compartment high temperature), some scenes need to be extended to- 55℃~150℃；

implementation methodThe testing machine needs to be compatible with high and low temperature environmental chambers (built-in or external docking), and the fixtures and drive system need to withstand high and low temperatures to avoid jamming and force drift caused by temperature changes;

精度保障The accuracy of force values needs to be maintained throughout the entire temperature range±0.5%（0.5 Grade), displacement accuracy≤±0.5%±1MmTo avoid testing errors caused by material hardening at low temperatures and softening at high temperatures;

Typical ApplicationsTest the insertion and extraction force attenuation of engine compartment wiring harness terminals and car charging gun plugs at high and low temperatures (such as- 40℃The insertion and extraction force should not exceed room temperature 1.5 Double).

2. Adaptation to humid and corrosive environments

Damp and hot conditions: Need support 40℃+95% RHWet heat cycle test (compliant withISO 6405-2Standard), the equipment needs to have anti condensation design (such as fixture rust prevention, sensor sealing);

corrosive environmentSome vehicles used in marine climate areas need to be tested after simulating salt spray corrosion. The testing machine fixtures should be made of stainless steel or anti-corrosion coatings (such as passivation treatment) to avoid corrosion affecting the clamping accuracy.

3. Vibration coupling testing capability

Vehicle components are subjected to both insertion and removal actions as well as body vibrations during driving, and the testing machine needs to support themplug and unplug+Vibration coupling test：

Vibration parameters: frequency10~2000HzAcceleration5~20g(Compliant with)ISO 16750-3Vibration standards);

Synchronous control: The insertion and removal action is triggered synchronously with the vibration signal, simulating the insertion and removal in real driving (such as slight shaking of the vehicle when inserting and removing a charging gun), ensuring that the test data is close to the actual working conditions.

2、 Mechanical performance requirements: high reliability and long life adaptation

The design lifespan of automotive electronic products is usually 10 year/ 24Ten thousand kilometers, the requirements for plug-in life and mechanical stability are much higher than those for consumer electronics:

1. Long cycle life and stability

number of cyclesConventional connectors (such as cabin wiring harness terminals) need to support5000~10000Repeated insertion and removal cycles, charging gunOBDThe interface needs to support10000~30000The testing machine needs to ensure continuous cycling (maximum number of cycles)≥10⁶Secondary);

Stability of force valuesIn a long-term cycle (such as 10000 The peak insertion and extraction force fluctuates≤±5%To avoid data distortion caused by equipment fatigue;

drive systemPriority should be given to electronic servo drives (rather than pneumatic ones) to ensure smooth and impact free insertion and removal, simulating gentle insertion and removal in real use (to avoid damaging the terminals).

2. Wide force value and speed range adaptation

Force rangeCovering the insertion and extraction force range of in car products（5~50N）Special products (such as heavy-duty truck wiring harness terminals) need to be extended to100NResolution of force values≥0.01N(Capture small sudden changes in force values, such as a decrease in force values caused by terminal wear);

speed range: Support0.5~50mm/minLow speed plugging and unplugging (simulating manual operation) and1~10time/High speed plugging and unplugging in seconds (simulating automated assembly lines), speed accuracy≤±1%Ensure consistency in testing across different scenarios.

3. Adaptation of foolproof and directional design

Car mounted connectors often come with foolproof structures (such as buckles and locating pins), and the testing machine needs to have:

Precision guidance mechanism: coaxial insertion and removal≤0.1mmTo avoid terminal bending and abnormal force values caused by eccentric insertion and removal;

Buckle action simulation: Supports“plug and unplug+Buckle locking/unlock”Integrated testing, capturing the peak force value when the buckle is unlocked (such as≤30NTo avoid users being unable to unlock.

3、 Electrical synchronization testing requirements: Mechanics+Electrical performance linkage verification

The core risk of automotive electronics is“Electrical failure caused by poor contact”If there is a signal interruption or abnormal charging during driving, the testing machine needs to synchronously monitor the electrical performance:

1. Synchronous testing of contact resistance

test scope：0.01mΩ~1ΩTerminal contact resistance is usually required≤10mΩ）, Resolution≥0.01mΩ；

synchronicitySynchronize the collection of force and resistance data during the insertion and extraction process (sampling frequency)≥2000Hz）, generate“力-displacement-resistance”Three dimensional curve, visually identifying the critical point of poor contact (such as the force value during a sudden change in resistance)/Displacement);

Anti interference designThe equipment needs to have electromagnetic shielding function (compliant withISO 11452Electromagnetic compatibility standards are used to avoid interference from the electromagnetic environment of the vehicle, such as engine ignition and radar signals, in measuring resistance.

2. Conducting voltage drop and insulation test (optional)

The model needs to support conduction voltage drop testing (range)0~5V, Resolution0.01V）Verify high current scenarios (such as charging guns)30AThe influence of terminal heating of current on contact performance;

Insulation resistance test (range)1MΩ~1GΩ）To avoid the risk of leakage caused by insulation layer wear during the plugging and unplugging process (in accordance withGB/T 18487.1Charging safety standards).

4、 Automation and batch testing requirements: adapted to the production efficiency of the automotive manufacturing industry

Automotive electronic components are mostly mass-produced (single batch) 10 ten thousand+）The testing machine needs to meet the requirements of efficient quality inspection:

1. Multi station synchronous testing

support4~16Workstation parallel testing (conventional) 8 Workstation), different workstations can independently set parameters (such as different insertion and extraction times, speed) to improve batch inspection efficiency;

Consistency between workstations: Error in force values at each workstation≤±1%To avoid qualification judgment deviation caused by differences in workstations.

2. Automated loading, unloading, and sorting

The production line scene needs to integrate automatic feeding modules (such as vibration discs and robotic arms) to achieve“material fetching-test-sorting”Full process automation, reducing manual intervention;

Unqualified product judgment: automatically judged as qualified based on the range of insertion and extraction force, resistance threshold, and number of cycles/Unqualified, supportedNGProduct labeling (such as laser marking) and data traceability.

3. Data Networking and Compliance

supportMES(Production Execution System) networking, automatic uploading of test data to the enterprise database, achieving product batch traceability (compliant)IATF 16949Quality management system requirements);

Software function: It has audit tracking, user permission management, and data tamper proof functions, meeting the compliance requirements of the automotive industry for test data.

5、 Fixtures and safety requirements: adapted to the characteristics of automotive products

1. Special fixture design

Compatible with different types of car connectors, such as circular connectors（M12/M16）Rectangular connector（USCARStandard), charging gun plug（GB/T 18487.1）The fixture needs to have a quick mold change function (mold change time)≤5 Minutes);

Clamping stability: using pneumatic or vacuum fixtures, adjustable clamping force（5~20N）To avoid damaging the product casing or terminals, and to prevent the sample from slipping during the insertion and removal process.

2. Security protection function

Overload protection: When the insertion and extraction force exceeds the set threshold (such as the rated force)120%）Automatically stop the machine to avoid terminal bending and equipment damage;

Emergency stop and protection: equipped with a physical emergency stop button and a transparent protective cover (to prevent debris splashing), in compliance withISO 13849Safety standards;

High temperature protection: During high and low temperature testing, the interface between the equipment and the environmental box should be sealed to avoid personnel burns caused by high temperature gas leakage.

6、 Industry standard compliance requirements

The automotive electronics industry has strict international standards/According to domestic standards, the testing machine must meet the following criteria:

Mechanical properties:ISO 6405(Testing Method for Automotive Connectors)USCAR-2(North American Automotive Connector Standard)GB/T 25085(Environmental conditions and testing of electrical and electronic equipment for road vehicles);

Electrical performance:ISO 11452(Electromagnetic compatibility testing)GB/T 18487.1(Conductive charging system for electric vehicles);

Quality Assurance:IATF 16949The automotive industry quality management system requires equipment to have calibration certificates and data traceability.

7、 Selection recommendation and summary

1. Recommended device configuration

Drive type: electronic servo type（0.5 Grade accuracy);

Force range:0~100N(covering the vast majority of in car products);

Environmental adaptation:-40~120℃High and low temperature environmental chamber, supporting vibration coupling testing;

Extended function: synchronous testing of contact resistance（0.01mΩ Resolution)8~16WorkstationMESNetworking and automatic sorting;

Fixture: Quick mold changing fixture for car connectors (compatible with circular)/rectangle/Charging gun).

2. summary

The core requirements of the automotive electronics industry for plug-in force testing machines are “Environmental adaptation, mechanical performance stabilization, electrical testing synchronization, production efficiency automation, data compliance traceability”When selecting, priority should be given to high and low temperatures/Vibration coupling capability, long cycle stability, synchronous testing of contact resistance, while ensuring that the equipment meets industry standards andIATF 16949Compliance requirements to avoid distortion of test data and failure to meet product reliability standards due to insufficient equipment.