CN117825192A - DC charging pile cable bending life test system and method - Google Patents
DC charging pile cable bending life test system and method Download PDFInfo
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- CN117825192A CN117825192A CN202311753611.9A CN202311753611A CN117825192A CN 117825192 A CN117825192 A CN 117825192A CN 202311753611 A CN202311753611 A CN 202311753611A CN 117825192 A CN117825192 A CN 117825192A
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- 238000012360 testing method Methods 0.000 title claims abstract description 107
- 238000000034 method Methods 0.000 title claims abstract description 31
- 238000005452 bending Methods 0.000 title claims abstract description 27
- 238000012806 monitoring device Methods 0.000 claims abstract description 17
- 238000003825 pressing Methods 0.000 claims description 8
- 238000000926 separation method Methods 0.000 claims description 7
- 230000006835 compression Effects 0.000 claims description 5
- 238000007906 compression Methods 0.000 claims description 5
- 238000012544 monitoring process Methods 0.000 claims description 5
- 238000005056 compaction Methods 0.000 claims description 2
- 230000008569 process Effects 0.000 abstract description 16
- 230000008859 change Effects 0.000 abstract description 15
- 230000002159 abnormal effect Effects 0.000 abstract description 6
- 230000005856 abnormality Effects 0.000 abstract description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 8
- 239000004020 conductor Substances 0.000 description 6
- 239000002390 adhesive tape Substances 0.000 description 4
- 238000012986 modification Methods 0.000 description 4
- 230000004048 modification Effects 0.000 description 4
- 230000000712 assembly Effects 0.000 description 3
- 238000000429 assembly Methods 0.000 description 3
- 238000010998 test method Methods 0.000 description 3
- 238000002788 crimping Methods 0.000 description 2
- 238000007405 data analysis Methods 0.000 description 2
- 238000002224 dissection Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000007619 statistical method Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
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Abstract
The invention relates to a system and a method for testing the bending life of a DC charging pile cable, comprising the following steps: swing testing machine: the device comprises a charging pile cable sample, a charging device and a control device, wherein the charging pile cable sample is used for driving the charging pile cable sample which is fixedly connected to swing for a preset times at a preset swinging frequency and a preset swinging angle under the condition of applying a preset external force; the monitoring device is electrically connected with cable cores of the two ends of the charging pile cable sample extending out of the swing testing machine and forms a series closed loop so as to monitor impedance in real time and provide a broken wire alarm; the monitoring device monitors and acquires the impedance value of the charging pile cable sample in real time in the swinging process of the charging pile cable sample, and gives an alarm when the wire breakage abnormality occurs, so that judgment can be made in time when the test failure or abnormal condition occurs in the test process, the test is terminated, and the effective time of the test is saved; on the other hand, the impedance change rate data of the charging pile cable sample in the swinging process can be obtained after the obtained impedance value is monitored and recorded, and the impedance change rate data is an important parameter for evaluating the bending life of the charging pile cable sample.
Description
Technical Field
The invention relates to the technical field of cables, in particular to a system and a method for testing the bending life of a DC charging pile cable.
Background
The new energy charging pile cable is used as a key component of a new energy automobile charging system, and technology development demand update iteration of the new energy automobile industry follows. In order to meet the rapid charging requirement, a large square DC charging mode is widely applied, but the DC charging pile cable is repeatedly bent to different degrees inevitably in the use process due to large wire diameter and large weight per unit length, and the charging gun can bear pressure on the cable when placed, so that the fatigue life test of a certain angle and a certain load is required to be carried out on the cable torsion life test product of the charging gun. According to the bending test method in IEC 62196-1 standard, a sample is fixed on a swing test machine, and as shown in figure 1, the main structure of the swing test machine comprises a charging gun head shell for the sample to pass through, a wire clamp for fixedly connecting the sample with the charging gun head shell, a swing shaft for driving the charging gun head shell and the sample to swing left and right by a certain angle, and a limit guide wheel for limiting the left and right movement distance of a non-swing part of the sample; and in combination with the figure 2, a certain weight of load is applied to the test sample, and after the test sample swings for a set number of times under the drive of the swinging shaft, the condition of the disconnection rate of a power line and a signal line is inspected and used for evaluating the fatigue life of the DC charging pile cable. The test method can only judge the abnormality of the sample cable after the end of a complete test period, and can not make life assessment if the abnormality or test disqualification occurs in the test process, but the complete test period needs about 10-12 hours, so that the waste of test time is caused.
Disclosure of Invention
In view of the above-mentioned shortcomings of the prior art, the present invention aims to provide a system and a method for testing the bending life of a DC charging pile cable, which are capable of obtaining impedance change rate data by increasing real-time monitoring impedance, so as to timely judge whether a test is failed or abnormal in the test process, thereby terminating the test and saving the test effective time; meanwhile, the impedance change rate data can also be used as one of important parameters for evaluating the bending life of the charging pile cable.
To achieve the above and other related objects, the present invention provides the following technical solutions:
a DC charging stake cable bending life test system, comprising:
swing testing machine: the device comprises a charging pile cable sample, a charging device and a control device, wherein the charging pile cable sample is used for driving the charging pile cable sample which is fixedly connected to swing for a preset times at a preset swinging frequency and a preset swinging angle under the condition of applying a preset external force;
and the monitoring device is electrically connected with cable cores of the two ends of the swing testing machine, which extend out of the cable sample of the charging pile, and forms a series closed loop so as to monitor the impedance in real time and provide a broken wire alarm.
According to the technical scheme, the charging pile cable sample is fixed on the swing testing machine, the cable cores extending out of the two ends of the swing testing machine are electrically connected with the monitoring device to form a series closed loop, the swing testing machine drives the charging pile cable to swing for preset times at preset swing frequency and swing angle under the condition of applying preset external force, the monitoring device monitors and acquires the impedance value of the charging pile cable sample in real time during swing of the charging pile cable sample, and gives an alarm when wire breakage abnormality occurs, so that judgment can be made in time when test disqualification or abnormal conditions occur during the test, the test is terminated, and the effective time of the test is saved; on the other hand, the impedance change rate data of the charging pile cable sample in the swinging process can be obtained after the obtained impedance value is monitored and recorded, and the impedance change rate data can be used as an important parameter for evaluating the bending life of the charging pile cable sample in the data analysis stage.
As one of the preferred aspects of the present application, the compression separation assembly further comprises: the device comprises a charging pile cable sample, a power line, a sheath and a connecting rod, wherein the charging pile cable sample is used for charging the power line at two ends of the charging pile cable sample; and the two ends of the charging pile cable sample with the pressing and separating assembly extend out of the swing testing machine completely.
The technical scheme is realized, and the compaction separation assembly applies pressure to the power line and separates the power line from the outer sheath so as to simulate the terminal crimping state in actual use.
As one of preferable aspects of the present application, the swing testing machine includes:
charging gun head shell: one end of the charging pile cable sample penetrates out and is electrically connected with the external signal wire;
wire clamp: the cable sample of the limited charging pile is fixedly connected with the charging gun head shell;
swing axle: driving the fixedly connected charging gun head shell to swing for a preset times at a preset swinging frequency and a preset swinging angle;
spacing guide pulley: and forming a channel for the other end of the charging pile cable sample to pass through and limiting the left-right movement distance of the charging pile cable.
According to the technical scheme, one end of the charging pile cable sample penetrates through the charging gun head shell from the wire clamp, the cable core without the outer sheath completely stretches out of the charging gun head shell, the wire clamp limits the charging pile cable sample so that the charging pile cable is fixedly connected with the charging gun head shell, the other end of the charging pile cable sample penetrates through a channel formed between the limiting guide wheels, the charging gun head shell is fixedly connected with the swinging shaft so as to swing for preset times at preset swinging frequency and swinging angle under the driving of the swinging shaft after the application of preset external force, and the bending life evaluation test of the charging pile sample is completed.
As one of the preferable modes of the present application, the monitoring device includes a connection signal line electrically connected to the cable cores of the two ends of the swing testing machine from which the charging pile cable sample extends, and an impedance tester electrically connected to the connection signal line.
According to the technical scheme, the impedance tester can monitor the impedance of the charging pile cable in the swing test process and give an alarm when the disconnection condition is detected.
On the other hand, the application also provides a method for testing the bending life of the DC charging pile cable, which comprises the following steps:
s1, fixing a charging pile cable sample to drive the charging pile cable sample to swing at a preset swing frequency and a preset swing angle for a preset number of times under the condition of applying a preset external force;
s2, the cable cores of the charging pile cable samples extending out of the two ends of the swing testing machine are electrically connected with a monitoring device for monitoring impedance in real time and giving out a disconnection alarm to form a series connection closed loop.
As one of preferred embodiments of the present application, S1 includes:
the method comprises the steps that compression separation assemblies which apply pressure to power lines and separate the power lines from an outer sheath are arranged on the power lines at two ends of a charging pile cable sample;
fixing the cable sample of the charging pile on the swing testing machine so that two ends with the pressing and separating assembly extend out of the swing testing machine completely.
As described above, the present invention has the following advantageous effects:
the invention provides a system and a method for testing the bending life of a DC charging pile cable, wherein the system comprises the following steps: swing testing machine: the device comprises a charging pile cable sample, a charging device and a control device, wherein the charging pile cable sample is used for driving the charging pile cable sample which is fixedly connected to swing for a preset times at a preset swinging frequency and a preset swinging angle under the condition of applying a preset external force; the monitoring device is electrically connected with cable cores of the charging pile cable samples extending out of two ends of the swing testing machine and forms a series closed loop so as to monitor impedance in real time and provide a broken wire alarm; the monitoring device monitors and acquires the impedance value of the charging pile cable sample in real time in the swinging process of the charging pile cable sample, and gives an alarm when the wire breakage abnormality occurs, so that judgment can be made in time when the test failure or abnormal condition occurs in the test process, the test is terminated, and the effective time of the test is saved; on the other hand, the impedance change rate data of the charging pile cable sample in the swinging process can be obtained after the obtained impedance value is monitored and recorded, and the impedance change rate data can be used as an important parameter for evaluating the bending life of the charging pile cable sample in the data analysis stage.
Drawings
Fig. 1 shows a cross-sectional view of an embodiment of the invention.
Fig. 2 is a diagram illustrating a swing state according to an embodiment of the present invention.
Corresponding part names are indicated by numerals and letters in the drawings:
1. charging pile cable samples; 11. a cable core; 2. a swing testing machine; 21. a charging gun head housing; 22. a wire clamp; 23. a swing shaft; 24. limiting guide wheels; 3. externally hung weights; 4. a monitoring device; 41. connecting a signal line; 42. an impedance tester.
Detailed Description
Further advantages and effects of the present invention will become apparent to those skilled in the art from the disclosure of the present invention, which is described by the following specific examples.
Please refer to fig. 1-2. It should be understood that the structures, proportions, sizes, etc. shown in the drawings are for illustration purposes only and should not be construed as limiting the invention to the extent that it can be practiced, since modifications, changes in the proportions, or otherwise, used in the practice of the invention, are not intended to be critical to the essential characteristics of the invention, but are intended to fall within the spirit and scope of the invention. Also, the terms such as "upper," "lower," "left," "right," "middle," and "a" and the like recited in the present specification are merely for descriptive purposes and are not intended to limit the scope of the invention, but are intended to provide relative positional changes or modifications without materially altering the technical context in which the invention may be practiced.
Referring to fig. 1, the present invention provides a system for testing bending life of a cable of a DC charging pile, comprising: swing testing machine 2: the device comprises a charging pile cable sample 1, a charging pile sensor, a sensor and a sensor, wherein the charging pile cable sample 1 is used for driving the fixed connection to swing at a preset swinging frequency and a preset swinging angle for a preset number of times under the condition of applying a preset external force; the monitoring device 4 is electrically connected with the cable cores 11 of the two ends of the charging pile cable sample 1, which extend out of the swing testing machine 2, and forms a series closed loop to monitor the impedance in real time and provide a disconnection alarm. Specifically, the swing testing machine 2 includes: charging gun head housing 21: one end of the cable sample 1 for the charging pile penetrates out to be electrically connected with an external signal wire; wire clamp 22: the cable sample 1 of the limited charging pile is fixedly connected with the charging gun head shell 21; swing shaft 23: driving the fixedly connected charging gun head shell 21 to swing for a preset number of times at a preset swinging frequency and a swinging angle; limit guide pulley 24: a passage through which the other end of the charging pile cable sample 1 passes is formed and the distance of the left and right movement of the charging pile cable is restricted. The monitoring device 4 includes: the connection signal line 41 electrically connected to the cable cores 11 of the two ends of the swing testing machine 2 from which the charging pile cable sample 1 extends, and the impedance tester 42 electrically connected to the connection signal line 41, the impedance tester 42 in this embodiment being a multichannel impedance tester 42.
In order to simulate the state of terminal crimping in actual use, a compressing and separating assembly for applying pressure to the power line and separating the power line from the outer sheath is arranged on the power line of the two ends of the charging pile cable sample 1 extending out of the swing testing machine 2. Specifically, the pressing and separating assembly in this embodiment includes a strong adhesive tape for winding the outside of the power line to bundle the power line and a clip fastened to the outside of the strong adhesive tape.
The method for testing the bending life of the DC charging pile cable, which is developed by the system for testing the bending life of the DC charging pile cable disclosed by the embodiment, comprises the following detailed steps:
1. sample preparation:
1.1 sample name: DC charging pile cable (od=38.0±0.5 mm);
1.2 sample length: 1.5 m/root;
1.3 sample volume: a total of 2 groups, a group of 5, a total of 10 samples;
1.4 sample processing: and stripping the outer jackets at two ends of the charging pile cable sample by 100mm, reserving the length of the signal wire by 100mm, exposing the power wire by 50mm, and stripping the insulating layer of the power wire by 20mm to expose the copper conductor.
2. Setting test conditions:
2.1 test environment: ambient temperature: 25 ℃ ± 5 relative humidity: less than 55%;
2.2 test conditions:
number of sways: 20000 cycles;
swing frequency: 60 cycles/min;
swing angle: vertical direction + -45 DEG;
and (3) applying an external force: 100N.
3. The test steps are as follows:
s1, arranging compression separation assemblies which apply pressure to the power lines and separate the power lines from an outer sheath on the power lines at two ends of a charging pile cable sample 1;
fixing the charging pile cable sample 1 to drive the swing testing machine 2 which swings for a preset times at a preset swing frequency and a swing angle under the condition of applying a preset external force, wherein when the charging pile cable sample 1 is fixed on the swing testing machine 2, two ends with compression separation assemblies extend out of the swing testing machine 2 completely;
specifically, the power lines at the two ends of the cable sample 1 of the charging pile are wound by a strong adhesive tape and clamped by a clamp, so that the power lines are separated from the outer sheath; then, one end of the charging pile cable sample 1 passes through the charging gun head shell 21 from the wire clamp 22, and the strong adhesive tape and the clamp fully extend out of the charging gun head shell 21; the other end of the charging pile cable sample 1 passes through a channel formed by the limiting guide wheel 24; clamping the wire clamp 22 so that the wire clamp 22 restricts the charging pile cable sample 1 to fixedly connect the charging pile cable sample 1 with the charging gun head shell 21; meanwhile, the charging gun head housing 21 is fixedly connected with the swinging shaft 23. Specifically, referring to fig. 1 in detail, the swinging shaft 23 includes a housing portion and a shaft portion rotatably connected to the housing portion, and the housing portion is sleeved on the charging gun head housing 21 and locked and fixed by a locking screw. The swing shaft 23 drives the charging pile cable sample 1 to swing at a preset swing frequency and a preset swing angle for a preset number of times in a state where the charging pile cable sample 1 is applied with a preset external force.
S2, the cable cores 11 of the charging pile cable sample 1 extending out of the two ends of the swing testing machine 2 are electrically connected with the monitoring device 4 for monitoring impedance in real time and giving out a disconnection alarm to form a series closed loop.
Specifically, the connection signal line 41 is electrically connected with one end of the charging pile cable sample 1 extending out of the charging gun head housing 21, and is connected in series to the positive stage of the impedance tester 42; the other end of the charging pile cable sample 1 is electrically connected with the connecting signal wire 41 and is connected to the negative level of the impedance tester 42 in series, and the charging pile cable sample 1, the connecting signal wire 41 and the impedance tester 42 form a closed loop, so that the functions of real-time monitoring of impedance and disconnection alarming are realized.
In this embodiment, as shown in fig. 1 and 2, an externally hung weight 3 of 100N is added to a charging pile cable sample 1, the swinging shaft 23 swings for 20000 cycles at a swinging frequency of 60 cycles/min and a swinging angle of ±45° in the vertical direction, the impedance tester 42 monitors and obtains real-time impedance values in the 20000 cycle swinging test processes, and if a line break occurs in the process, the test can be terminated by alarming, or if an abnormal impedance value occurs, so that the test effective time is saved.
According to the test condition requirement, other parameters of the test condition are kept unchanged, the center distance L between the limiting guide wheels 24 is adjusted, 10 groups of different L values are taken for comparison test, and the 10 groups of L values are respectively: OD-5mm, OD, OD+5, OD+10mm, OD+15mm, OD+20mm, OD+25mm, OD+30mm, OD+35mm, OD+40mm (where OD is the outer diameter of the sample cable in mm). The method comprises the steps of respectively carrying out comparison tests of different L values by adopting 10 charging pile cable samples 1, obtaining impedance change rates of the 10 charging pile cable samples 1 under the different L values and copper wire breakage rates after the dissection, calculating to obtain bending radius R values of the different L values, and evaluating the influence degree of the different L values on test results by counting the impedance change rates and the copper wire breakage rates after the dissection, thereby being used for standardizing test parameter setting and test method operation.
Table 1: comparative test data for different L values
The impedance change rate of each core wire conductor in the test process is respectively monitored by an impedance tester 42, the maximum value is taken as reference data, and the impedance change rate is less than 5 percent and is judged to be qualified;
analyzing each sample after the test, and calculating the copper wire breakage rate = number of broken wires/total number of conductors of each core wire conductor to obtain the copper wire breakage rate percent of the conductor, wherein the copper wire breakage rate percent is less than 3 percent, and the conductor is judged to be qualified;
the national standard GB/T12706-2008 specifies the minimum cable bend radius: the minimum bend radius of the unshielded cable is 15 times the outer diameter of the cable. The outer diameter of the finished cable is 38mm and the minimum bending radius of the cable is 570mm according to standard requirements. According to the standard of the charging pile cable, the minimum bending radius R of the charging pile cable is larger than 304mm, namely when the minimum bending radius R is larger than 8 xOD, the impedance change rate is smaller than 5%, the copper wire breakage rate is smaller than 3%, and the fatigue life requirement is met.
According to the requirements of a charging pile cable standard IEC 62196-12022, under the condition that the center distance L of the limiting guide wheel 24=cable OD+20mm, namely 8X OD, is obtained according to the test result, the test result is accurate;
similarly, the center distance l= =8×od parameter of the limiting guide wheel 24 is kept unchanged, the distance H between the lower edge position of the wire clamp 22 and the center point of the swinging shaft 23 is adjusted, and according to the test result, the distance h= +50- +100mm between the lower edge position of the wire clamp 22 and the center point of the swinging shaft 23 is obtained by combining the requirements of the charging pile cable standard IEC 62196-12022, and the test result is accurate.
According to the system and the method for testing the bending life of the DC charging pile cable, the impedance in the swing test process is monitored and obtained in real time through the impedance tester 42, so that impedance change rate data are obtained; on one hand, the method can be used as an important parameter for evaluating the bending life, and on the other hand, the method can also make a judgment in time when the test is unqualified or abnormal in the test process, so that the test is terminated, and the effective time of the test is saved. By means of statistical analysis of the impedance change rate and the after-analysis copper wire breakage rate and combining with requirements of a charging pile cable standard IEC 62196-12022, specific parameters of the center distance L between the limiting guide wheels 24 and the distance H between the lower edge position of the wire clamp 22 and the center point of the swinging shaft 23, which can obtain accurate test results, can be obtained in limited tests, test parameter setting is unified, and test accuracy is improved.
The above embodiments are merely illustrative of the principles of the present invention and its effectiveness, and are not intended to limit the invention. Modifications and variations may be made to the above-described embodiments by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is intended that all equivalent modifications and variations of the invention be covered by the claims, which are within the ordinary skill of the art, be within the spirit and scope of the present disclosure.
Claims (6)
1. A DC charging stake cable bending life test system, comprising:
swing testing machine (2): the device comprises a charging pile cable sample (1) for driving fixed connection to swing at a preset swing frequency and a preset swing angle for a preset number of times under the condition of applying preset external force;
the monitoring device (4) is electrically connected with the cable cores (11) of the two ends of the swing testing machine (2) extending out of the charging pile cable sample (1) and forms a series closed loop so as to monitor impedance in real time and provide disconnection alarm.
2. The DC charging pile cable bending life test system of claim 1, further comprising a compression separation assembly: the device is used for applying pressure to power lines at two ends of the charging pile cable sample (1) and separating the power lines from the outer sheath; and two ends of the charging pile cable sample (1) with the pressing and separating assembly extend out of the swing testing machine (2) completely.
3. The DC charging pile cable bending life test system according to claim 1, wherein the swing testing machine (2) comprises:
charging gun head shell (21): one end of the charging pile cable sample (1) penetrates out to be electrically connected with the external signal wire;
wire clip (22): the limited charging pile cable sample (1) is fixedly connected with the charging gun head shell (21);
swing shaft (23): driving the fixedly connected charging gun head shell (21) to swing for a preset times at a preset swinging frequency and a preset swinging angle;
limiting guide wheel (24): a passage through which the other end of the charging pile cable sample (1) passes is formed and the left-right movement distance of the charging pile cable is limited.
4. The monitoring device (4) according to claim 1, characterized in that the monitoring device (4) comprises a connection signal line (41) electrically connected with the cable cores (11) of the charging pile cable sample (1) extending out of both ends of the swing testing machine (2), and an impedance tester (42) electrically connected with the connection signal line (41).
5. The method for testing the bending life of the DC charging pile cable is characterized by comprising the following steps of:
s1, fixing a charging pile cable sample (1) and driving the charging pile cable sample to swing at a preset swing frequency and a preset swing angle for a preset times under the condition of applying a preset external force;
s2, electrically connecting cable cores (11) of the charging pile cable sample (1) extending out of two ends of the swing testing machine (2) with a monitoring device (4) for monitoring impedance in real time and giving out a disconnection alarm to form a series connection closed loop.
6. The method of claim 5, wherein S1 comprises:
a compaction separation assembly for applying pressure to the power line and separating the power line from the outer sheath is arranged on the power lines at two ends of the charging pile cable sample (1);
fixing the charging pile cable sample (1) on the swing testing machine (2) so that two ends with the pressing and separating assembly completely extend out of the swing testing machine (2).
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311753611.9A CN117825192A (en) | 2023-12-19 | 2023-12-19 | DC charging pile cable bending life test system and method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311753611.9A CN117825192A (en) | 2023-12-19 | 2023-12-19 | DC charging pile cable bending life test system and method |
Publications (1)
| Publication Number | Publication Date |
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| CN117825192A true CN117825192A (en) | 2024-04-05 |
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ID=90514429
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311753611.9A Pending CN117825192A (en) | 2023-12-19 | 2023-12-19 | DC charging pile cable bending life test system and method |
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| Country | Link |
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| CN (1) | CN117825192A (en) |
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2023
- 2023-12-19 CN CN202311753611.9A patent/CN117825192A/en active Pending
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