Charging interface plug-in life test system: reducing manual testing errors

In the reliability testing of charging interfaces such as Type-C and USB-A, plug and unplug life is one of the core indicators, and it is necessary to simulate more than 10000 plug and unplug scenarios to verify durability. Traditional manual testing is susceptible to factors such as operating habits and physical condition, with error rates often reaching 8% -15%Charging interface plug-in life test systemThrough automation and standardized design, errors can be significantly reduced to ensure the accuracy of test data.

1、 Cracking the pain points of manual testing errors

There are three main sources of error in manual testing: firstly, unstable insertion and extraction force. When manually plugging and unplugging, the force is prone to decay with the increase of testing time (such as from the initial 50N to 35N), resulting in inconsistent degrees of interface wear; Secondly, there is a deviation in the angle of insertion and extraction. Manual operation is difficult to ensure that each insertion and extraction is parallel to the interface axis, and the angle deviation may reach ± 5 °, which can accelerate the damage of interface terminals and misjudge their lifespan; Thirdly, data recording lags behind. Manual counting of insertion and removal times and recording of failed nodes are prone to omissions and errors, especially in 10000 tests where the data error rate can reach over 10%.

2、 How to achieve low error testing in the system

Firstly, automated execution ensures operational consistency. The system precisely controls the insertion and extraction force (accuracy ± 0.5N) and angle (deviation ≤ 0.1 °) through servo motors, and can preset national or industry standard parameters (such as the Type-C interface insertion and extraction force requirements in GB/T 26248). The fluctuation of force and angle does not exceed 2% in 10000 tests, avoiding random errors caused by manual operation.

Secondly, real-time data collection eliminates recording bias. The system is equipped with force sensors, displacement sensors, and high-definition cameras, which can synchronously collect changes in insertion and extraction force, interface displacement, and appearance wear. The data sampling frequency reaches 100Hz, and each insertion and extraction data is automatically stored in the database without manual intervention. The data recording accuracy is high, and visual curves can be generated to intuitively present the process of the interface from normal to failure.

Moreover, environmental control reduces external interference. Part of the system integrates a constant temperature and humidity chamber, which can simulate high temperature (60 ℃), high humidity (90% RH) and other working conditions. The testing process is closed without manual contact, avoiding the influence of hand sweat, dust and other factors on interface performance, further reducing testing errors caused by environmental factors, and making the results more in line with actual usage scenarios.

　　Charging interface plug-in life test systemBy replacing manual operation with technological means, the testing error is controlled within 3%, which not only provides reliable product quality basis for enterprises, but also promotes the standardized development of charging interface detection field.