The customer's problem
A manufacturer of liquid-cooled DC charging connectors for commercial vehicles and depot charging solutions wanted to bring a new generation of MCS-compatible connector systems rated up to 3,000 A to production readiness. The requirements included robust derating curves, consistently low contact resistance over numerous mating cycles, and verification of protection ratings following climatic changes and mechanical stress. In addition, the locking mechanism, sensors and communication had to operate reliably while the connector was undergoing thermal characterization under high current. Validation was required in accordance with common automotive and component standards (e.g. DIN EN 60512, ISO 20653, LV 214/LV 215) and OEM-specific supplements such as MAN M3499-1 and 2, as well as the brand-new draft standards IEC 63379 and IEC 62196-1.
Solution by AUCOTEAM
AUCOTEAM implemented a modular high-current test environment based on the “Heart of Test” platform. The setup combines safe high-voltage power supply with synchronous multi-channel measurement technology for voltage drops per contact, contact resistance, contact and coolant temperatures, flow rate and pressure. Special derating stations allow for defined thermal boundary conditions, including multi-point temperature measurement and accompanying IR thermography for hotspot evaluation.
For environmental simulation, climate tests (temperature cycling, humidity, icing), shock and vibration, corrosion (salt spray), UV radiation, as well as dust and water tests—including ice water immersion testing—were combined. The functional tests included latching, mating/disconnecting cycles, compression/tensile tests, leak testing after preloading, insulation and dielectric strength tests, as well as monitoring of interface communication. Test bench control, bus simulation, and automated data acquisition enabled reproducible load profiles, clear acceptance criteria and complete traceability.
Key Features of the AUCOTEAM Solution
- Quick campaign startup thanks to a reusable high-current test rack with an integrated HV safety chain, insulation monitoring, and a standardized GUI.
- Seamless integration of climate chambers, corrosion chambers, shakers and solar exposure—including high-current load running in parallel.
- Measurement concept with high-resolution temperature and voltage drop measurement per contact for precise derating curves and early detection of degradation.
- Automated reports with trend analyses for contact resistance, ΔT at the contact, leakage and IP behavior – ideal for design iterations and supplier discussions.
- Proven methodology from multiple connector campaigns (charging inlets and plugs) shortens development cycles and reduces validation costs.
