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
