Design and optimization of a charging cable test system

Abstract

This master’s thesis focuses on the mechanical design and implementation of hardware fixtures for testing high-power, uncooled electric vehicle (EV) charging cables. The work was carried out in collaboration with LUT University and Kempower to improve inefficiencies in the current laboratory testing process. Existing test setups rely heavily on manual procedures, including ad-hoc cable positioning, taped-on temperature sensors, and fixed charging inlets designed for only one charging standard. These methods reduce testing repeatability, affect measurement consistency, and increase the time required for test preparation.

The main objective of the project was to improve testing repeatability and simplify laboratory operations by developing a more standardized testing interface. The project resulted in three functional prototypes: a helical drum mounting system for maintaining proper cable spacing and cooling conditions, a tool-less temperature sensor clamp with an integrated open-loop copper interface, and a modular interchangeable inlet system capable of supporting test currents up to 500 A. Together, these solutions improve measurement consistency, reduce manual setup work, and provide a flexible platform for future charging standards such as the Megawatt Charging System (MCS) and the North American Charging Standard (NACS).