New Energy Testing Equipment

1.1 New Energy Configuration List

1.2 Introduction to the Plan
The inspection of new-energy vehicles is divided into two parts: electrical safety testing and power battery & vehicle safety testing. Based on these two aspects, specialized testing equipment has been developed—namely, the New-Energy Electrical Safety Testing System and the Power Battery & Vehicle Safety Testing System.
Testing Standards
GB/T 44500—2024 Regulations for Safety Performance Inspection of New Energy Vehicles
 

1.3 Inspection Items

1.4 Inspection Equipment
1.4.1 Introduction to the Device
(1) Electrical Safety Inspection Equipment
The electrical safety inspection equipment for new-energy vehicles is a specialized series of tools designed to assess the insulation resistance of high-voltage components, ensure equipotentiality between exposed metal conductors on the vehicle body and other elements, and verify the safety of DC charging systems. Primarily, it conducts inspections by employing anti-electric shock detection and DC charging test function units, collecting and analyzing relevant data from the vehicle under test. This enables comprehensive safety checks throughout the entire charging process, as illustrated in the figure below.

(2) Power Battery and Complete Vehicle Safety Testing Equipment
New-energy vehicle power battery and whole-vehicle safety inspection equipment is a specialized series of tools designed for the discharge testing of power batteries, as well as safety assessments of motors and electronic control systems. These tools primarily conduct dynamic inspections by placing vehicles on test benches and simulating equivalent operating conditions, enabling the collection and analysis of relevant data from both the inspected vehicles and the testing equipment itself. This process facilitates the evaluation of critical safety parameters such as power battery integrity, motor performance, and electronic control system reliability. Depending on the type of vehicle being tested, the equipment is categorized into passenger car inspection systems and commercial vehicle inspection systems—specifically, the passenger car inspection setup is illustrated in the figure below.

1.4.2 Technical Specifications
(1) Electrical Safety Inspection Equipment

(2) Power Battery and Complete Vehicle Safety Testing Equipment

1.4.3 Technical Features
(1) Electrical Safety Inspection Equipment
Electric Shock Detection Module
The test boasts high precision, with safety compliance accuracy as high as ±1%. It ensures safe operation through automatic overvoltage, overcurrent, short-circuit, and leakage protection features. Additionally, it incorporates a multi-in-one functional unit equipped with advanced multi-channel automatic switching capability.
DC Charging Detection Module
The sampling accuracy is high, and it precisely measures the voltage and current parameters of the high-voltage charging circuit by integrating high-precision voltage and current sensors with the module's analog signal processing capabilities.
Charging Gun Switch Module
The switching function is powerful, enabling fully programmable control to route all test cables to the respective functional units. This significantly reduces both the number of wiring harnesses and the frequency of harness connections, thereby shortening vehicle inspection time.
Networked Communication
By using a standard communication interface, it can be networked with other automotive diagnostic equipment.
Convenient and quick operation
The testing software is simple to learn, easy to maintain and upgrade; throughout the entire testing process, the driver only needs to follow the on-screen prompts to connect the wiring harness, start the test, and disconnect the harness.
(2) Power Battery and Complete Vehicle Safety Testing Equipment
High-precision synchronization control
Adopting a high-precision variable-frequency control system, it ensures precise, stable, and reliable operation.
Modular Design
The software features a modular design, making it easy to upgrade and maintain.
Error-Defensive
The system is equipped with a self-locking mechanism, automatically alarms in case of errors, and features an emergency stop function—ensuring complete safety without any potential hazards.
User interface comfort
The interface is user-friendly, with consistent window styles throughout, logical functionality divisions, and an operational approach that aligns with mainstream usage habits.
Environmental Adaptability
Each key component is equipped with dust-proof features, and the selected core components boast a high waterproof rating.
1.4.4 Software Features