EV Equipment Testing Jig
This project involved a complete redesign and rebuild of an existing electrical test jig used for quality verification of electric vehicle chargers. The original jig had been previously developed by another designer, but it required major modifications to meet updated technical and safety requirements.
The redesign included:
– a new base plate and main frame redesign,
– a redesigned electrical connection interface for reliable plug-in operation,
– integration of 3D-printed positioning and connector components,
– a re-routed wiring layout for improved accessibility and maintenance,
– and new polycarbonate safety covers protecting the operator from exposed conductors.
After completing the mechanical and electrical redesign, the jig was fully assembled, functionally tested, and prepared for introduction on the production line.
This jig represents one of approximately thirty test and assembly jigs I’ve designed or re-engineered throughout my career, illustrating a practical approach to reverse engineering, design improvement, and adaptation of existing tooling to new functional and health & safety standards.