Daily calibration and maintenance techniques for the immersion testing machine of the charging gun plug-in life solution

　　Charging gun plug-in life solution immersion testing machineAs the core equipment for simulating the durability of charging guns in harsh environments, its testing accuracy is directly related to the charging safety of electric vehicles. The lack of daily calibration and maintenance may result in a deviation of over 5% in the number of insertions and removals, or loss of control of solution concentration leading to test failure. Therefore, establishing a systematic operation and maintenance process is crucial.

Calibration work needs to cover both mechanical and chemical parameters in two dimensions. In the mechanical part, the positioning accuracy of the insertion and extraction mechanism needs to be verified weekly with a laser displacement sensor to ensure that the insertion depth error of the charging gun does not exceed ± 0.5mm. The insertion and extraction force sensor needs to be calibrated monthly with a standard force value weight to ensure that the error within the range of 100-500N is ≤ ± 2N. The calibration of the solution system is more critical, and the pH sensor needs to be calibrated daily with three standard buffer solutions of 4.01, 7.00, and 10.01 to prevent concentration deviation of acid rain simulation solution (pH3.0) or seawater solution (pH8.1); The salinity meter needs to be calibrated with 35 ‰ standard saline water every week to ensure that the concentration of sodium chloride solution is controlled within ± 1 ‰.

A maintenance schedule needs to be developed for consumable components. The guide shaft of the insertion and extraction mechanism needs to be coated with special silicon-based grease every 5000 cycles to avoid metal wear and displacement of the insertion and extraction angle; The sealing gasket needs to be inspected monthly, and if cracks or hardening occur, it should be replaced immediately to prevent solution leakage and corrosion of the robotic arm. The maintenance of the solution tank is particularly important. It is necessary to clean the inner walls with citric acid solution every week to remove salt spray crystal residues. At the same time, the filter element (precision 5 μ m) should be replaced to avoid impurities blocking the spray holes and affecting the uniformity of solution distribution.

The stability maintenance of environmental parameters is crucial. The equipment workshop should maintain a constant temperature (23 ± 2 ℃), and when the humidity exceeds 60%, the dehumidifier should be turned on to prevent water vapor condensation from affecting the sensitivity of the insertion and extraction force sensor. The compressed air pipeline needs to be drained and discharged quarterly to ensure that the working pressure of the driving cylinder is stable at 0.6-0.8MPa, and to avoid deviation in insertion and removal speed due to pressure fluctuations (standard speed 100mm/s, allowable error ± 5mm/s).

The maintenance of data recording and fault warning systems can improve equipment reliability. Before daily testing, it is necessary to verify the previous calibration data to ensure that the software displays a maximum deviation of ± 1 insertion and removal times from the mechanical counter; Regularly export fault logs, focusing on the frequency of warning messages such as "low solution level" and "motor overload", and replacing aging level sensors or motor carbon brushes in advance. By establishing a closed-loop management system of "calibration maintenance recording", it is possible toCharging gun plug-in life solution immersion testing machineThe repeatability of the test data has been improved to over 98%, providing continuous and reliable technical support for the life assessment of the charging gun.