Charger connector tester

Don’t let the unassuming title fool you – this exciting project a part of the latest trends, as the setup will test charging busbars for electric vehicles at Norsk Hydro ASA (Precision Tubing Tønder)!  

The sensitive part of the tested component is in fact the adapter box between busbars and the cars battery, which must be waterproof and electrically safe. The tester performs a HiPot test to check the isolation between the cable-cores. The tester operates at more than 4kV DC with an allowable leakage current of some μA and performs a ground continuity test between connector housing and the cable shielding.  

The battery connector must be mechanically tested for water resistance using air with a leakage test at 1.5psi. The entire test is performed in one 30 second cycle, which yields high capacity. Further production automation is already in scope and the tester is adaptable into a roundtable solution.  

From a user perspective, the tester is simple and intuitive to use, providing clear results and statistics via a touchscreen and a dedicated LabVIEW software application, and 4 operating modes are available. The machine is built with a focus on user safety, and surfaces are adapted for easy maintenance including lubrication and cleaning that are a part of a quality-assured production.  

We are excited to be a part of bringing more e-vehicles on roads.