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E-mail
2212240822@qq.com
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Phone
18911395947
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Address
514, Unit 1, Building 2, Xingfu Square, Gu'an County, Langfang City, Hebei Province
Product Categories
- Voltage breakdown tester
- Insulation material volume resistance tester
- Low temperature brittleness temperature tester
- Plastic brittleness temperature testing machine
- Rope tension machine
- Paper film tensile machine
- Dielectric strength testing machine
- Ceramic Electrical Strength Tester
- Filter integrity tester
- Folding filter bubble point tester
Beijing Beiguang Jingyi Instrument Equipment Co., Ltd
Epoxy resin board withstand voltage tester
NegotiableUpdate on 01/19
- Model
- Nature of the Manufacturer
- Producers
- Product Category
- Place of Origin
Overview
The epoxy resin board withstand voltage tester complies with the standard $r $nGB1408.1-2016 "Test Methods for Electrical Strength of Insulation Materials - Part 2: Power Frequency Test" $r $nGBT13542.1-2009 "Test Methods for Power Frequency Breakdown Voltage Strength and Endurance of Vulcanized Rubber" $r $nGB/T1695-2005 "Test Methods for Power Frequency Breakdown Voltage of Cable Paper" $r $nGB/T3333-1999
Product Details
Epoxy resin board withstand voltage tester
Product Model:BDJC-10KVTheBDJC-50KVTheBJC-100KV
Product brand: Beijing Beiguang Jingyi
Control method: computer-controlled
meet the standardGB/T1408TheASTM D149TheIEC60243-1wait
Applicable materials: rubber, plastic, film, ceramic, glass, paint film, resin, wire and cable, insulation oil and other insulation materials
Test items: breakdown voltage test, dielectric strength test, electrical strength test, withstand voltage breakdown strength test, etc
Test voltage:10KVThe20KVThe50KVThe100KVThe150KVwait
Voltage accuracy:≤1%
Applicable materials: Insulation materials
Boosting rate:10V/S-5KV/S
Test method: communication/DC, withstand voltage, breakdown, gradient boost
Control system:PLCControl voltage boost
Core components: using imported accessories
Test medium: insulating oil, air
Display mode: curve display, data printing
Other features: Wireless Bluetooth control
Equipment composition: host, computer, electrode
Electrode specifications:25mmThe75mmThe6mm
Electrical capacity:3KVAThe5KVAThe10KVA
Voltage endurance time:0-8H
Security protection: Level 9 security protection
Warranty period: Three years, lifetime maintenance.
Training method: Engineer on-site training for installation
Certificate of issuance:514So304Institutions such as research institutes and scientific research institutes are all eligible
Host size:1000*600*1400mmThe1700*600*1400mm
Host weight:100KGThe200KG
Epoxy resin board withstand voltage testerSecurity protection measures function:
1The experiment is conducted in the test box, and when the door of the test box is opened, the power supply cannot be applied to the input terminal of the high-voltage transformer, that is, there is no voltage on the high-voltage side.100KVThe close distance between the high-voltage electrode of the testing equipment and the wall of the testing chamber is270mm，50KVThe close distance between the high-voltage electrode of the testing equipment and the wall of the testing chamber is250mmEven if people come into contact with the box wall during the experiment, there will be no danger.
2The equipment should be equipped with a separate protective grounding wire. Grounding protection is mainly used to reduce the strong electromagnetic interference caused by the breakdown of the sample to the surrounding area. It can also prevent the computer from losing control.
3The circuit of the test equipment is equipped with multiple protection measures, mainly including overcurrent protection, overvoltage protection, leakage protection, short circuit protection, DC test discharge alarm, electromagnetic discharge, etc.
4DC test discharge alarm function:When the device completes the DC test,When the test door is opened, the equipment will automatically sound an alarm,The alarm will automatically cancel after the discharge device on the equipment is used to discharge.(Note: Failure to discharge electricity after DC testing may pose a danger to human safety,Cannot directly take the electrode,Remind users to discharge to avoid injury).
5Experimental discharge device, automatic discharge placement of electromagnet.
betaware:
1Independent control system,Modular structure facilitates after-sales maintenance,Beautiful appearance,There was no noise throughout the entire experimental process,Electric level automatic centering and positioning,easy to operate,safety factor,High precision.
2Operated and controlled by the touch screen and control panel of the device itself,If curve analysis is not required,No computer is required.
3If curve analysis is required,Equipped with a computer,Only perform data and curve recording functions,Do not perform device control,Avoiding the alternating operation of testers between computers and equipment,更人性化。
4The equipment has test parameters,The same experimental conditions do not need to be set for each experiment,And even when the power is cut off, the parameters set for one experiment after getting drunk will still be remembered.
5The experimental interface is simple and clear,And accompanied by a schematic curve explanation,Different parameters,Different curve trends,Easy to understand.
6The control panel is simple and concise,Clear functional labeling,Easy to operate.
7Can record and display simultaneously10Test record,Facilitate comparative analysis of experimental data. And any set of data that is not ideal can be discarded at any time.
8AddedUDisk download function,You can directly download the test records from the device toUIn the plate.
9If equipped with a computer,Can generate detailed test reports,Including each set of body information,Multiple sets of comprehensive information,And the curve.
10The equipment testing interface adopts the method of instrument panel and digital simultaneous and real-time display,More convenient for viewing the experimental process.
11The device has safety warning prompts,The test cannot start without closing the test chamber door,And a warning will pop up,At Full Degree(namely:High voltage transformer has no output)A warning will pop up at that time,And during the experiment, if the door is opened,The experiment will automatically end.
12Using Bluetooth data transmission,Resolve the inconvenience caused by the presence of isolation walls blocking the passage of wires through walls and ensure safe and reliable remote operations;
13The equipment is equipped with a three color warning light,When the green light is on, it indicates that the box door is well closed and the test can begin,When the yellow light is on, it indicates that the test chamber door is open,At this point, the sample can be replaced. When the red light is on, it indicates high voltage0.5KV,Do not open the door at this time. The warning light will flash and sound an alarm during the discharge process after the DC test is completed.(summary:The green light box door is well closed,Yellow light, open the door carefully,Red light has high voltage)
instrument composition:
1Boosting components:The boosting part is composed of a voltage regulator and a boosting transformer;
2Drive components:Controller and motor uniformly adjust the boost transformer for motor input;
3Testing components:Measurement circuit composed of integrated circuits;
4Computer measurement and control system;
5Box control system
Instrument advantages:
1Automatic discharge;
2AC voltage and DC voltage testing errors1%;
3The electrode bracket adoptsYQuality epoxy board;
4The software is capable of continuous operation10Comparison of group experiments;
5Different colors of experimental curves,Stackable comparison;
6The software can set current protection function;
7Equipped with a host control area,Can control the host independently without using a computer;
8The host has voltage and current display functions;
9Built in exhaust system;
10Built in lighting function;
11Discharge alarm device;
12Bluetooth remote control;
13Three color light alarm device(The green light box door is well closed,Yellow light, open the door carefully,Red light has high voltage);
14Can achieve dual operation of touch screen or computer;
15Can achieve combinatorial programming,The boost and withstand times of gradient boosting can be set separately;
16TheUDisk download function,You can directly download the test records from the device toUIn the plate.
Introduction to two testing methods of paint film power frequency voltage breakdown tester:
The selection of experimental methods is carried out in the system settings. It should be noted that during the communication experiment,Need to insert the silicon stack short-circuit rod. During the DC test, it is necessary to pull out the short-circuit rod of the silicon stack,To avoid affecting the experimental coefficients,And discharge operation must be carried out after the DC test is completed,To prevent residual electricity from posing a danger to experimental personnel,The discharge process involves swinging the discharge rod back and forth,The alarm light flashes during the discharge process,buzzer alarm,Need to wait for the buzzer to stop sounding the alarm,The warning light is no longer flashing,Only then can the door of the test chamber be opened.
Introduction to Three Experimental Methods:
Continuous boost:Continuous boost is divided into two types: fast boost and slow boost,Among them, rapid boosting refers to uniformly boosting the sample voltage from zero at a selected boosting rate,Until the sample is punctured,The breakdown voltage is the voltage value at the moment of breakdown. Slowly boost the sample voltage from zero to the initial voltage,After reaching the initial voltage, boost the voltage at the selected rate until the sample breaks down,The breakdown voltage is the voltage value at the moment of breakdown.
Step by step voltage increase:The sample voltage rapidly increases from zero to the initial voltage,After reaching the initial voltage, the gradient holding time is used as the length of time,stable voltage,Continue to increase the pressure at the selected rate after the gradient time has ended,Stabilize the voltage after reaching the next gradient voltage value,This process continues until the sample breaks down. The determination of breakdown voltage can be divided into two situations,The sampling method can be selected in the sample settings.
Instantaneous boost:The sample voltage directly reaches the initial voltage,Maintain the set voltage for a certain period of time until the sample breaks down,The breakdown voltage is the voltage value at the moment of breakdown.
Breakdown determination and data collection.When the material reaches the dielectric strength pole, the current suddenly increases and the voltage suddenly changes. The control system captures the abnormal current signal through high-precision sensors and records the peak voltage at this time as the breakdown voltage value (unit:kV/mm）. After data processing, key parameters such as breakdown strength and withstand voltage time are automatically generated, supporting graphical display and export.
Electrode system
Using brass or stainless steel electrode material (ball)-Ball, board-The surface of the board is precisely polished to reduce edge discharge interference and ensure uniform electric field distribution.
Closed-loop control system
Pre set parameters such as boost rate and voltage threshold on the computer or touch screen interface, dynamically adjust the boost curve to avoid step like fluctuations, and ensure testing accuracy≤2%.
Differences in testing modes
Destructive breakdown testBy continuously increasing the voltage, the dielectric strength limit of the material can be directly measured, which is suitable for material performance evaluation and quality inspection in the research and development stage.
Non destructive voltage withstand test
Apply a fixed threshold voltage (such as2Multiple rated voltage+1000V）And maintain the set duration (usually60Monitor whether the leakage current exceeds the standard in seconds to verify short-term insulation stability, which is often used for final inspection of production lines.
Security protection mechanismReal time protection system
Integrate multiple mechanisms such as overcurrent protection, short circuit protection, and leakage protection, automatically cutting off high-voltage output and starting discharge program when an abnormality is triggered.
Physical isolation design
Equipped with shielding covers and mechanical interlocking devices to prevent operators from coming into contact with high-voltage areas; Automatic power-off when the test hatch is opened to avoid the risk of arc damage.
Working principle and process
Parameter settings (boost rate)/Voltage upper limit) → 2.Sample installation and electrode calibration → 3.Start boosting and monitor in real-time → 4.Capture of breakdown signal → 5.Data recording and analysis.
Technical analysis of voltage breakdown tester
1、 Core functions and purposes
Performance evaluation of insulation materials
Test the breakdown strength of solid insulation materials (plastics, films, ceramics, resins, etc.) under power frequency or DC voltage（kV/mm）And withstand voltage time, providing key data support for fields such as power equipment and new energy.
Detect micro defects in materials (such as bubbles and cracks) to prevent equipment failures caused by insulation failure.
Multi domain applications
Power industry: Evaluate the voltage resistance performance of high-voltage cables and transformer insulators.
New energy: testing the dielectric properties of battery separators and motor insulation materials.
Research: Study the failure mechanism and optimization process of new insulation materials.
2、 Key technical parameters
voltage range
Output range:AC/DC 0-50kVContinuously adjustable,BDJC-100KVreachable100kV.
Boosting rate:100-3000V/sInfinite speed regulation to meet the gradient testing requirements of different materials.
Accuracy and Safety
Voltage measurement error≤2%Equipped with three-level interlocking protection (mechanical)/electron/Physical isolation).
Overcurrent protection, leakage protection, and automatic discharge function for DC testing ensure safe operation.
intelligent control
Dynamically drawing experimental curves, supporting automatic data storage andEXCEL/WORDExport.
The closed-loop control system monitors the boost curve in real time to avoid step like fluctuations.
3、 Standard system and testing methods
Chinese Standard
GB/T 1408.1-2006TheGB/T 1695-2005Wait, clarify the sample pretreatment, electrode specifications, and oil temperature control range (such as25±2℃）.
Comparison of International Standards
ASTM D149andIEC 60243There are differences in boosting methods, testing times, etc. (such asASTMAllow step boosting,IECOnly continuous boost is recognized.
test mode
Continuous boost: directly measure the critical value of breakdown voltage.
Voltage withstand test: Maintain the specified voltage for a specified duration to verify the stability of the material.
4、 Operating standards and precautions
Environmental and sample requirements
ambient humidity≤80%The sample must be clean, dry, and strictly protected from dust and light.
Liquid media (such as transformer oil) need to control temperature fluctuations±2℃.
safe operation
At least two people should cooperate and direct contact with the electrodes and the inside of the oil cup is prohibited.
The equipment needs to be independently grounded to prevent electromagnetic interference from causing data abnormalities.
instrument calibration
Adopting a four level calibration system (including temperature compensation design) to ensure stable output of the high-voltage coil.
5、 Selection and Development Trends
Key points for equipment selection
Support multiple standards first（GBTheIECTheASTM）The intelligent modelBDJCSeries.
Pay attention to the accuracy of boost rate regulation and the anti-interference ability of data acquisition.
Technical upgrade direction
integrationAIAlgorithm optimization testing efficiency, development of high temperature/Low temperature environment adaptation module.
Enhance remote monitoring capabilities to meet industrial needs4.0Automated testing requirements.
What is the relationship between insulation strength and breakdown voltage?
1、 Definition and Basic Relationship
breakdown voltage
definitionThe critical voltage value at which an insulating material loses its insulation properties and becomes a conductor under the action of a strong electric field.
unit: Kilovolts（kV）Or volts（V）.
Insulation strength (breakdown field strength)
definitionThe electric field strength that a unit thickness of insulation material can withstand reflects the material's own electrical resistance.
unit: Kilovolts/Millimeter（kV/mm）Or megavolts/Rice（MV/m）.
2、 Difference and Connection
Differences in physical meaning
breakdown voltageCharacterize the compressive limit of a material at a specific thickness, which is directly related to the thickness of the material.
Insulation strengthThe ability to withstand electric fields per unit thickness of a material is an inherent property of the material itself.
Differences in application scenarios
Insulation strengthUsed for horizontal comparison of insulation performance of different materials (such as plastics, ceramics, etc.).
breakdown voltageGuide the design of electrical equipment to determine the thickness of the insulation layer or the safe voltage threshold.
influencing factors
Insulation strengthMainly determined by material composition, microstructure, and temperature (such as susceptibility to thermal breakdown at high temperatures).
breakdown voltageIn addition to the material itself, it is also affected by thickness, environmental temperature and humidity, and voltage type (AC)/DC (Direct Current) impact.
3、 Typical applications
Material screeningHigh insulation strength materials (such asE=30kV/mmCeramics are suitable for the insulation layer of high-voltage transformers.
equipment designUsing the breakdown voltage formula to deduce the small thickness of insulation layer (such as cable insulation layer design).
safety assessmentVerify the reliability of long-term operation of power equipment by combining the relationship between the two (such as testing of photovoltaic module packaging materials)
summary
Insulation strength is an inherent property of a material to resist electric field damage, while breakdown voltage is its thickness dependent withstand voltage performance. The two are related through mathematical formulas, providing a core basis for evaluating the performance of insulation materials and designing electrical equipment together
The breakdown voltage testing methods mainly include the following types and operating procedures:
1、 Classification of testing methods
Power frequency AC breakdown test
principleApply power frequency AC voltage and gradually increase the voltage until the sample breaks down, record the breakdown voltage value.
step：
Sample installation between electrodes (such as enameled wire wrapped around cylindrical electrodes).
Set the boost rate (such as100-500V/s）.
Continuously boost until breakdown, record breakdown voltage.
DC breakdown test
principleEvaluating the insulation performance of materials under stable electric fields using direct current voltage.
step：
Connect to a DC high-voltage power supply, with a slow boost rate (e.g50-200V/s）.
Observe the changes in current and record the voltage value at the moment of breakdown.
Pulse breakdown test
principleSimulate transient overvoltage (such as lightning strikes) and test the insulation strength of materials under high-frequency or pulse conditions.
step：
Apply standard waveform pulse voltage (such as lightning impulse waveform).
Record the breakdown voltage after multiple impacts.
Partial discharge and thermal breakdown testing
partial dischargeMonitor internal discharge signals of insulation materials and evaluate potential defects.
Thermal breakdownCombining temperature rise and pressure rise, test the pressure resistance of materials at high temperatures.
2、 General operating procedures
Preparation phase
Check the equipment connection wires, electrode contact status, and sample integrity.
Set environmental conditions (temperature, humidity) and wear protective equipment (insulated gloves, goggles).
Device connection and parameter settings
High voltage power supply connected to electrodes, series voltage/ammeter.
Select boost mode (constant or step boost) and range.
Test Execution
Activate the boost system and monitor the voltage in real-time/Current variation.
After breakdown, the power will be automatically cut off and data will be recorded. Repeat the test and take the average value.
safety protection
Equipment configuration includes overcurrent protection, door interlock, and discharge device.
After DC testing, manual discharge is required to avoid electric shock.
3、 Testing standards and equipment configuration
Applicable standard
International Standard：ASTM D149(Solid material dielectric breakdown test).
domestic standard：GB/T 1408.1-2006(Electrical strength test of insulation materials).
Core parameters of equipment
voltage range: Covering communication/direct current0-150kV(such asBDJC-50KVModel).
pressure rate：0.05-5kV/sadjustable.
Electrode designCircular electrode (diameter)25/75mm）Reduce the noise of edge playback.
4、 Typical application scenarios
photovoltaic materials：EVAThe packaging material needs to be verified for power frequency/DC breakdown strength.
enameled wireEvaluate the limit voltage of the insulation layer through AC or DC testing.
Cable and TransformerVoltage withstand test ensures long-term stability of equipment operation.
The above methods evaluate the insulation performance of materials from multiple dimensions to ensure the safety and compliance of electrical equipment
Breakdown voltage detection in product safety compliance testing
1、 Testing standards and specifications
International Standard
IEC 60243-1 Definition of basic terms, test conditions, and procedures for high-voltage testing, applicable to breakdown voltage testing of electrical equipment and materials.
ASTM D149 Electrical strength testing for solid insulation materials, including determination of breakdown voltage.
domestic standard
GB/T 1408.1-2006 Specify the electrical strength test method for insulation materials and clarify the power frequency/DC breakdown test process.
GB/T 4074.5 Special standard for breakdown voltage testing of enameled wire, requiring verification of the ultimate withstand voltage performance of the insulation layer.
2、 Testing process and operation
Sample preparation
Clean and dry the surface of the sample to avoid contamination or moisture affecting the test results.
Select electrode clamp based on material type (such as enameled wire, mica sheet, silicon carbide).
Device Configuration
Use a voltage breakdown tester (such asBDJC-50KVModel), supports communication/direct current0-150kVtest scope.
Series voltage/Real time data monitoring with ammeter, equipped with overcurrent protection and door interlock device to ensure safety.
Parameter Setting and Execution
Set the boost rate according to the standard (such as100-500V/s）Voltage type (power frequency)/DC) and environmental temperature and humidity.
Gradually increase the voltage until breakdown occurs, record the critical voltage value, and repeat the test to take the average value.
3、 Compliance verification objectives
Security performance verification
Determine the breakdown field strength (withstand voltage per unit thickness) of insulation materials to prevent equipment from causing fires or short circuits due to insulation failure.
Detect potential defects (such as paint film pinholes, impurities) to ensure that the product has no local insulation weak points.
standard compliance
Verify complianceIEC 60851-5(enameled wire)UL 1449Access requirements for industries such as electrical equipment.
Through accelerated aging testing (high temperature)/Simulate long-term use scenarios with high humidity and evaluate material durability.
4、 Typical application scenarios
enameled wireTest the limit voltage of the insulation layer (such as10kVOptimize the painting process and select qualified products (as mentioned above).
mica sheetThrough power frequency breakdown test（200kV）Verify insulation reliability in high-temperature environments.
Silicon carbide（SiC）Evaluate its breakdown voltage stability in high-voltage power electronic equipment.
5、 Safety protection measures
Operating SpecificationsWear insulated gloves and goggles, maintain a safe distance to prevent arc injuries.
Equipment maintenanceRegularly calibrate instruments, manually discharge after testing to avoid residual voltage risks.
emergency responseConfigure emergency stop button and first aid equipment to ensure quick response in case of emergencies.
6、 Test report and improvement
Record the breakdown voltage, breakdown location, and environmental parameters, and analyze whether the data meets the design expectations.
By comparing the test results of different processes or materials, optimize the production process and promote technological innovation.
Through the above process, breakdown voltage testing can effectively ensure product safety and compliance, while providing scientific basis for the long-term stable operation of electrical equipment
Precautions for using voltage breakdown tester and dielectric strength tester (withstand voltage tester):
When using a voltage breakdown tester/When conducting breakdown strength tests on vulcanized rubber or other insulation materials using a dielectric strength tester (voltage tester), it is necessary to strictly comply with safety regulations and ensure the accuracy of the test results. The following is a detailed explanation of key precautions:
1、 Safety protection measures
1. High voltage hazard protection
Operators must receive safety training on high-voltage equipment and be familiar with the emergency stop button and power-off process of the equipment.
Set warning signs in the testing area (such as“High Voltage Danger”）Prohibit unrelated personnel from approaching.
The equipment must be reliably grounded (grounding resistance)≤4Ω）To avoid electric leakage or static electricity accumulation.
2. protective device
Ensure that the testing instrument is equipped with a safety interlock device (such as automatic power-off when the protective cover is not closed).
Use insulation operators (such as high-voltage insulation gloves, insulation pads) to assist in the operation.
3. Personal protective equipment（PPE）
Wear insulated gloves to avoid electric arcs or damage from flying objects.
2、 Equipment setup and calibration
1. Voltage parameter setting
Boosting rate: according to standards (such asASTM D149）Choose an appropriate speed (usually500 V/sor100 V/s）.
Initial voltage: from0Start gradually increasing the pressure to avoid sudden high voltage impact on the sample.
2. Electrode selection and installation
Use standard electrodes (such as spherical or cylindrical electrodes) that comply withIEC 60243Requirement).
Ensure that the electrode surface is flat, clean, and free of oxidation or stains (can be wiped with alcohol).
3. Calibration and Verification
Regularly calibrate equipment (voltmeter and ammeter accuracy must meet standard requirements).
Verify the accuracy of the equipment using standard samples with known breakdown voltage.
3、 Sample processing and testing conditions
1. sample preparation
The sample thickness is uniform (usually1-3 mm）No bubbles, impurities or mechanical damage.
Clean and dry the surface (avoid hand sweat, dust, or grease contamination).
2. environmental control
temperature23±2℃Humidity:50±5% RH(Refer to standard requirements).
Avoid electromagnetic interference (stay away from power equipment or high-frequency signal sources).
3. Sample fixation and contact
Ensure that the sample is in close contact with the electrode to avoid partial discharge caused by air gaps.
Slight pressure can be applied to soft rubber samples (such as1 N）Ensure a snug fit.
4、 Test process operation specifications
1. Gradually increase the voltage
Slowly increase the voltage to avoid misjudging the breakdown point due to sudden voltage changes.
Real time monitoring of current (sudden increase in current at breakdown moment).
2. Breakdown determination
Breakdown standard: When the current exceeds the set threshold (such as5 mA）Or the sample may undergo carbonization or perforation.
At least test the same sample at different positions3Next, take the average (excluding outliers).
3. data recording
Record the breakdown voltage, sample thickness, environmental conditions, and breakdown mode (such as surface discharge or through breakdown).
5、 Post test processing and maintenance
1.
Residual charge release
2.
Product Name: Voltage breakdown tester
Product Model:BDJC-10KVTheBDJC-50KVTheBJC-100KV
Product brand: Beijing Beiguang Jingyi
Control method: computer-controlled
meet the standardGB/T1408TheASTM D149TheIEC60243-1wait
Applicable materials: rubber, plastic, film, ceramic, glass, paint film, resin, wire and cable, insulation oil and other insulation materials
Test items: breakdown voltage test, dielectric strength test, electrical strength test, withstand voltage breakdown strength test, etc
Test voltage:10KVThe20KVThe50KVThe100KVThe150KVwait
Voltage accuracy:≤1%
Applicable materials: Insulation materials
Boosting rate:10V/S-5KV/S
Test method: communication/DC, withstand voltage, breakdown, gradient boost
Control system:PLCControl voltage boost
Core components: using imported accessories
Test medium: insulating oil, air
Display mode: curve display, data printing
Other features: Wireless Bluetooth control
Equipment composition: host, computer, electrode
Electrode specifications:25mmThe75mmThe6mm
Electrical capacity:3KVAThe5KVAThe10KVA
Voltage endurance time:0-8H
Security protection: Level 9 security protection
Warranty period: Three years, lifetime maintenance.
Training method: Engineer on-site training for installation
Certificate of issuance:514So304Institutions such as research institutes and scientific research institutes are all eligible
Host size:1000*600*1400mmThe1700*600*1400mm
Host weight:100KGThe200KG
Function of safety protection measures for voltage breakdown tester:
1The experiment is conducted in the test box, and when the door of the test box is opened, the power supply cannot be applied to the input terminal of the high-voltage transformer, that is, there is no voltage on the high-voltage side.100KVThe close distance between the high-voltage electrode of the testing equipment and the wall of the testing chamber is270mm，50KVThe close distance between the high-voltage electrode of the testing equipment and the wall of the testing chamber is250mmEven if people come into contact with the box wall during the experiment, there will be no danger.
2The equipment should be equipped with a separate protective grounding wire. Grounding protection is mainly used to reduce the strong electromagnetic interference caused by the breakdown of the sample to the surrounding area. It can also prevent the computer from losing control.
3The circuit of the test equipment is equipped with multiple protection measures, mainly including overcurrent protection, overvoltage protection, leakage protection, short circuit protection, DC test discharge alarm, electromagnetic discharge, etc.
4DC test discharge alarm function:When the device completes the DC test,When the test door is opened, the equipment will automatically sound an alarm,The alarm will automatically cancel after the discharge device on the equipment is used to discharge.(Note: Failure to discharge electricity after DC testing may pose a danger to human safety,Cannot directly take the electrode,Remind users to discharge to avoid injury).
5Experimental discharge device, automatic discharge placement of electromagnet.
meet the standard
GB1408.1-2016Test Method for Electrical Strength of Insulation Materials - Power Frequency Test - Part2Part of it
GBT13542.1-2009Thin film for electrical insulation
GB/T1695-2005Determination method for power frequency breakdown voltage strength and withstand voltage of vulcanized rubber
GB/T3333-1999Test Method for Power Frequency Breakdown Voltage of Cable Paper
betaware:
1Independent control system,Modular structure facilitates after-sales maintenance,Beautiful appearance,There was no noise throughout the entire experimental process,Electric level automatic centering and positioning,easy to operate,safety factor,High precision.
2Operated and controlled by the touch screen and control panel of the device itself,If curve analysis is not required,No computer is required.
3If curve analysis is required,Equipped with a computer,Only perform data and curve recording functions,Do not perform device control,Avoiding the alternating operation of testers between computers and equipment,更人性化。
4The equipment has test parameters,The same experimental conditions do not need to be set for each experiment,And even when the power is cut off, the parameters set for one experiment after getting drunk will still be remembered.
5The experimental interface is simple and clear,And accompanied by a schematic curve explanation,Different parameters,Different curve trends,Easy to understand.
6The control panel is simple and concise,Clear functional labeling,Easy to operate.
7Can record and display simultaneously10Test record,Facilitate comparative analysis of experimental data. And any set of data that is not ideal can be discarded at any time.
8AddedUDisk download function,You can directly download the test records from the device toUIn the plate.
9If equipped with a computer,Can generate detailed test reports,Including each set of body information,Multiple sets of comprehensive information,And the curve.
10The equipment testing interface adopts the method of instrument panel and digital simultaneous and real-time display,More convenient for viewing the experimental process.
11The device has safety warning prompts,The test cannot start without closing the test chamber door,And a warning will pop up,At Full Degree(namely:High voltage transformer has no output)A warning will pop up at that time,And during the experiment, if the door is opened,The experiment will automatically end.
12Using Bluetooth data transmission,Resolve the inconvenience caused by the presence of isolation walls blocking the passage of wires through walls and ensure safe and reliable remote operations;
13The equipment is equipped with a three color warning light,When the green light is on, it indicates that the box door is well closed and the test can begin,When the yellow light is on, it indicates that the test chamber door is open,At this point, the sample can be replaced. When the red light is on, it indicates high voltage0.5KV,Do not open the door at this time. The warning light will flash and sound an alarm during the discharge process after the DC test is completed.(summary:The green light box door is well closed,Yellow light, open the door carefully,Red light has high voltage)
instrument composition:
1Boosting components:The boosting part is composed of a voltage regulator and a boosting transformer;
2Drive components:Controller and motor uniformly adjust the boost transformer for motor input;
3Testing components:Measurement circuit composed of integrated circuits;
4Computer measurement and control system;
5Box control system
Instrument advantages:
1Automatic discharge;
2AC voltage and DC voltage testing errors1%;
3The electrode bracket adoptsYQuality epoxy board;
4The software is capable of continuous operation10Comparison of group experiments;
5Different colors of experimental curves,Stackable comparison;
6The software can set current protection function;
7Equipped with a host control area,Can control the host independently without using a computer;
8The host has voltage and current display functions;
9Built in exhaust system;
10Built in lighting function;
11Discharge alarm device;
12Bluetooth remote control;
13Three color light alarm device(The green light box door is well closed,Yellow light, open the door carefully,Red light has high voltage);
14Can achieve dual operation of touch screen or computer;
15Can achieve combinatorial programming,The boost and withstand times of gradient boosting can be set separately;
16TheUDisk download function,You can directly download the test records from the device toUIn the plate.
Main purpose and function This machine meets the requirementsGB1408.1-2006 GB1408.2-2006 GB/T1695-2005 GB/T3333 GB12656andASTM D149 ASTM D 876TheDIN53481TheUNI4291\\IECStandard requirements.Mainly suitable for testing the breakdown strength and withstand time of solid insulation materials such as plastics, films, resins, mica, ceramics, glass, insulation paints, etc. under power frequency voltage or DC voltage; This instrument is computer-controlled and can quickly and accurately collect, process, access, display, and print various data during the experimental process. This instrument has radiation protection function. The test door of the instrument is made of transparent insulated glass with a shielding mesh. During the test process, the current generated at the moment of breakdown poses a radiation hazard to the human body. Our company has conducted shielding treatment on this instrument to reduce the harm to human body. This instrument also has a lighting function, as there may be dark light during the testing process. This function can be applied to make the user's observation more obvious during the testing process, resulting in higher quality testing results.
Real time drawing of experimental curves, display of experimental data, accurate judgment, and the ability to save, analyze, and print experimental data. And it can automatically identify the breakdown of the sample and collect breakdown voltage data and leakage current. At the same time, it can quickly reduce the voltage and automatically reset to zero at the moment of breakdown. The software system is easy to operate, has stable performance, and is safe and reliable. Controlled by a computer, the data acquisition method effectively solves the anti-interference problem during the test process through photoelectric isolation. The software is easy to operate and can display dynamic curves in real time. At the same time, the boost rate is infinitely adjustable, and can be adjusted according to one's own needs. The adjustment range is0.1KV-3KV/SMake the boost rate truly uniform and accurate, and be able to accurately measure the data of leakage current.
Equipment composition principle and safety protection:1.The equipment mainly consists of high-voltage test transformers, contact voltage regulators, servo speed control systems, acquisition systems, control systems, automatic discharge, and other parts.2.The input of the test transformer is provided by the output of the voltage regulator, and the high voltage output is collected in real time by the acquisition system. The computer adjusts the speed control system that controls the rotation of the voltage regulator based on the voltage, forming a closed loop to make the voltage regulation process smoother. And it can meet the requirements of extremely slow voltage boosting.3.Automatically distinguish between AC and DC test processes. If the DC test is conducted and the test is completed, the discharge operation can be automatically carried out. During this period (without discharge), the test door will be opened, and there will be an audible and visual alarm to warn of danger!
Security protection: 1.Overcurrent protection: 1.1Low voltage side overcurrent protection to ensure safe operation of high-voltage transformers1.2High voltage side overcurrent protection, protecting the electrode surface from spark corrosion 1.3Exceeding the preset leakage current, cutting off the high voltage output2.High voltage power-off protection: 1.1Over range automatic cut-off of high voltage output 1.2During the experiment, the high voltage output can be manually turned off 1.3Voltage drop exceeds the preset value, cutting off high voltage output3.Output zero protection:1.1Before the experiment starts, if the high voltage output is not at zero position, give a prompt1.2If the high voltage output is not at zero, force it back to zero 4.Short circuit protection: 1.1High voltage output short circuit, automatically cut off output 1.2Low voltage input short circuit, automatic power-off5.Security door protection:1.1Unintentionally opening the cabin door during the experiment, automatically cutting off the output1.2Unable to start the experiment with the experimental cabin door open 1.3After the experiment, open the hatch and cut off the high-voltage output6.Software protection: Before starting each experiment, confirmation is required. Otherwise, a pop-up window will appear1.1Press the high voltage preparation switch, and the high voltage indicator light will turn on 1.2The experimental cabin door has been closed1.3Voltage regulator reset (high voltage output is zero)7.Discharge protection:1.1After the DC test, an audible and visual alarm is triggered when the cabin door is opened, and it is mandatory to discharge the pressure equalizing ball8.Leakage protection: 1.1Independent grounding protection 1.2Leakage protection switch
Introduction to two testing methods of paint film power frequency voltage breakdown tester:
The selection of experimental methods is carried out in the system settings. It should be noted that during the communication experiment,Need to insert the silicon stack short-circuit rod. During the DC test, it is necessary to pull out the short-circuit rod of the silicon stack,To avoid affecting the experimental coefficients,And discharge operation must be carried out after the DC test is completed,To prevent residual electricity from posing a danger to experimental personnel,The discharge process involves swinging the discharge rod back and forth,The alarm light flashes during the discharge process,buzzer alarm,Need to wait for the buzzer to stop sounding the alarm,The warning light is no longer flashing,Only then can the door of the test chamber be opened.
Introduction to Three Experimental Methods:
Continuous boost:Continuous boost is divided into two types: fast boost and slow boost,Among them, rapid boosting refers to uniformly boosting the sample voltage from zero at a selected boosting rate,Until the sample is punctured,The breakdown voltage is the voltage value at the moment of breakdown. Slowly boost the sample voltage from zero to the initial voltage,After reaching the initial voltage, boost the voltage at the selected rate until the sample breaks down,The breakdown voltage is the voltage value at the moment of breakdown.
Step by step voltage increase:The sample voltage rapidly increases from zero to the initial voltage,After reaching the initial voltage, the gradient holding time is used as the length of time,stable voltage,Continue to increase the pressure at the selected rate after the gradient time has ended,Stabilize the voltage after reaching the next gradient voltage value,This process continues until the sample breaks down. The determination of breakdown voltage can be divided into two situations,The sampling method can be selected in the sample settings.
Instantaneous boost:The sample voltage directly reaches the initial voltage,Maintain the set voltage for a certain period of time until the sample breaks down,The breakdown voltage is the voltage value at the moment of breakdown
Breakdown determination and data collection.When the material reaches the dielectric strength pole, the current suddenly increases and the voltage suddenly changes. The control system captures the abnormal current signal through high-precision sensors and records the peak voltage at this time as the breakdown voltage value (unit:kV/mm）. After data processing, key parameters such as breakdown strength and withstand voltage time are automatically generated, supporting graphical display and export.
Collaborative mechanism of key componentsThe high-voltage generator supports continuous output from 0-100 kV, and some customized models can reach a higher range; Meet different testing standard requirements (such as IEC 60243, ASTM D149) by switching between AC/DC/pulse modes.
Electrode system
Using brass or stainless steel electrode material (ball)-Ball, board-The surface of the board is precisely polished to reduce edge discharge interference and ensure uniform electric field distribution.
Closed-loop control system
Pre set parameters such as boost rate and voltage threshold on the computer or touch screen interface, dynamically adjust the boost curve to avoid step like fluctuations, and ensure testing accuracy≤2%.
Differences in testing modes
Destructive breakdown testBy continuously increasing the voltage, the dielectric strength limit of the material can be directly measured, which is suitable for material performance evaluation and quality inspection in the research and development stage.
Non destructive voltage withstand test
Apply a fixed threshold voltage (such as2Multiple rated voltage+1000V）And maintain the set duration (usually60Monitor whether the leakage current exceeds the standard in seconds to verify short-term insulation stability, which is often used for final inspection of production lines.
Security protection mechanismReal time protection system
Integrate multiple mechanisms such as overcurrent protection, short circuit protection, and leakage protection, automatically cutting off high-voltage output and starting discharge program when an abnormality is triggered.
Physical isolation design
Equipped with shielding covers and mechanical interlocking devices to prevent operators from coming into contact with high-voltage areas; Automatic power-off when the test hatch is opened to avoid the risk of arc damage.
Working principle and process
Parameter settings (boost rate)/Voltage upper limit) → 2.Sample installation and electrode calibration → 3.Start boosting and monitor in real-time → 4.Capture of breakdown signal → 5.Data recording and analysis.
Technical analysis of voltage breakdown tester
1、 Core functions and purposes
Performance evaluation of insulation materials
Test the breakdown strength of solid insulation materials (plastics, films, ceramics, resins, etc.) under power frequency or DC voltage（kV/mm）And withstand voltage time, providing key data support for fields such as power equipment and new energy.
Detect micro defects in materials (such as bubbles and cracks) to prevent equipment failures caused by insulation failure.
Multi domain applications
Power industry: Evaluate the voltage resistance performance of high-voltage cables and transformer insulators.
New energy: testing the dielectric properties of battery separators and motor insulation materials.
Research: Study the failure mechanism and optimization process of new insulation materials.
2、 Key technical parameters
voltage range
Output range:AC/DC 0-50kVContinuously adjustable,BDJC-100KVreachable100kV.
Boosting rate:100-3000V/sInfinite speed regulation to meet the gradient testing requirements of different materials.
Accuracy and Safety
Voltage measurement error≤2%Equipped with three-level interlocking protection (mechanical)/electron/Physical isolation).
Overcurrent protection, leakage protection, and automatic discharge function for DC testing ensure safe operation.
intelligent control
Dynamically drawing experimental curves, supporting automatic data storage andEXCEL/WORDExport.
The closed-loop control system monitors the boost curve in real time to avoid step like fluctuations.
3、 Standard system and testing methods
Chinese Standard
GB/T 1408.1-2006TheGB/T 1695-2005Wait, clarify the sample pretreatment, electrode specifications, and oil temperature control range (such as25±2℃）.
Comparison of International Standards
ASTM D149andIEC 60243There are differences in boosting methods, testing times, etc. (such asASTMAllow step boosting,IECOnly continuous boost is recognized.
test mode
Continuous boost: directly measure the critical value of breakdown voltage.
Voltage withstand test: Maintain the specified voltage for a specified duration to verify the stability of the material.
4、 Operating standards and precautions
Environmental and sample requirements
ambient humidity≤80%The sample must be clean, dry, and strictly protected from dust and light.
Liquid media (such as transformer oil) need to control temperature fluctuations±2℃.
safe operation
At least two people should cooperate and direct contact with the electrodes and the inside of the oil cup is prohibited.
The equipment needs to be independently grounded to prevent electromagnetic interference from causing data abnormalities.
instrument calibration
Adopting a four level calibration system (including temperature compensation design) to ensure stable output of the high-voltage coil.
5、 Selection and Development Trends
Key points for equipment selection
Support multiple standards first（GBTheIECTheASTM）The intelligent modelBDJCSeries.
Pay attention to the accuracy of boost rate regulation and the anti-interference ability of data acquisition.
Technical upgrade direction
integrationAIAlgorithm optimization testing efficiency, development of high temperature/Low temperature environment adaptation module.
Enhance remote monitoring capabilities to meet industrial needs4.0Automated testing requirements.
What is the relationship between insulation strength and breakdown voltage?
1、 Definition and Basic Relationship
breakdown voltage
definitionThe critical voltage value at which an insulating material loses its insulation properties and becomes a conductor under the action of a strong electric field.
unit: Kilovolts（kV）Or volts（V）.
Insulation strength (breakdown field strength)
definitionThe electric field strength that a unit thickness of insulation material can withstand reflects the material's own electrical resistance.
unit: Kilovolts/Millimeter（kV/mm）Or megavolts/Rice（MV/m）.
2、 Difference and Connection
Differences in physical meaning
breakdown voltageCharacterize the compressive limit of a material at a specific thickness, which is directly related to the thickness of the material.
Insulation strengthThe ability to withstand electric fields per unit thickness of a material is an inherent property of the material itself.
Differences in application scenarios
Insulation strengthUsed for horizontal comparison of insulation performance of different materials (such as plastics, ceramics, etc.).
breakdown voltageGuide the design of electrical equipment to determine the thickness of the insulation layer or the safe voltage threshold.
influencing factors
Insulation strengthMainly determined by material composition, microstructure, and temperature (such as susceptibility to thermal breakdown at high temperatures).
breakdown voltageIn addition to the material itself, it is also affected by thickness, environmental temperature and humidity, and voltage type (AC)/DC (Direct Current) impact.
3、 Typical applications
Material screeningHigh insulation strength materials (such asE=30kV/mmCeramics are suitable for the insulation layer of high-voltage transformers.
equipment designUsing the breakdown voltage formula to deduce the small thickness of insulation layer (such as cable insulation layer design).
safety assessmentVerify the reliability of long-term operation of power equipment by combining the relationship between the two (such as testing of photovoltaic module packaging materials)
summary
Insulation strength is an inherent property of a material to resist electric field damage, while breakdown voltage is its thickness dependent withstand voltage performance. The two are related through mathematical formulas, providing a core basis for evaluating the performance of insulation materials and designing electrical equipment together
The breakdown voltage testing methods mainly include the following types and operating procedures:
1、 Classification of testing methods
Power frequency AC breakdown test
principleApply power frequency AC voltage and gradually increase the voltage until the sample breaks down, record the breakdown voltage value.
step：
Sample installation between electrodes (such as enameled wire wrapped around cylindrical electrodes).
Set the boost rate (such as100-500V/s）.
Continuously boost until breakdown, record breakdown voltage.
DC breakdown test
principleEvaluating the insulation performance of materials under stable electric fields using direct current voltage.
step：
Connect to a DC high-voltage power supply, with a slow boost rate (e.g50-200V/s）.
Observe the changes in current and record the voltage value at the moment of breakdown.
Pulse breakdown test
principleSimulate transient overvoltage (such as lightning strikes) and test the insulation strength of materials under high-frequency or pulse conditions.
step：
Apply standard waveform pulse voltage (such as lightning impulse waveform).
Record the breakdown voltage after multiple impacts.
Partial discharge and thermal breakdown testing
partial dischargeMonitor internal discharge signals of insulation materials and evaluate potential defects.
Thermal breakdownCombining temperature rise and pressure rise, test the pressure resistance of materials at high temperatures.
2、 General operating procedures
Preparation phase
Check the equipment connection wires, electrode contact status, and sample integrity.
Set environmental conditions (temperature, humidity) and wear protective equipment (insulated gloves, goggles).
Device connection and parameter settings
High voltage power supply connected to electrodes, series voltage/ammeter.
Select boost mode (constant or step boost) and range.
Test Execution
Activate the boost system and monitor the voltage in real-time/Current variation.
After breakdown, the power will be automatically cut off and data will be recorded. Repeat the test and take the average value.
safety protection
Equipment configuration includes overcurrent protection, door interlock, and discharge device.
After DC testing, manual discharge is required to avoid electric shock.
3、 Testing standards and equipment configuration
Applicable standard
International Standard：ASTM D149(Solid material dielectric breakdown test).
domestic standard：GB/T 1408.1-2006(Electrical strength test of insulation materials).
Core parameters of equipment
voltage range: Covering communication/direct current0-150kV(such asBDJC-50KVModel).
pressure rate：0.05-5kV/sadjustable.
Electrode designCircular electrode (diameter)25/75mm）Reduce the noise of edge playback.
4、 Typical application scenarios
photovoltaic materials：EVAThe packaging material needs to be verified for power frequency/DC breakdown strength.
enameled wireEvaluate the limit voltage of the insulation layer through AC or DC testing.
Cable and TransformerVoltage withstand test ensures long-term stability of equipment operation.
The above methods evaluate the insulation performance of materials from multiple dimensions to ensure the safety and compliance of electrical equipment
Breakdown voltage detection in product safety compliance testing
1、 Testing standards and specifications
International Standard
IEC 60243-1 Definition of basic terms, test conditions, and procedures for high-voltage testing, applicable to breakdown voltage testing of electrical equipment and materials.
ASTM D149 Electrical strength testing for solid insulation materials, including determination of breakdown voltage.
domestic standard
GB/T 1408.1-2006 Specify the electrical strength test method for insulation materials and clarify the power frequency/DC breakdown test process.
GB/T 4074.5 Special standard for breakdown voltage testing of enameled wire, requiring verification of the ultimate withstand voltage performance of the insulation layer.
2、 Testing process and operation
Sample preparation
Clean and dry the surface of the sample to avoid contamination or moisture affecting the test results.
Select electrode clamp based on material type (such as enameled wire, mica sheet, silicon carbide).
Device Configuration
Use a voltage breakdown tester (such asBDJC-50KVModel), supports communication/direct current0-150kVtest scope.
Series voltage/Real time data monitoring with ammeter, equipped with overcurrent protection and door interlock device to ensure safety.
Parameter Setting and Execution
Set the boost rate according to the standard (such as100-500V/s）Voltage type (power frequency)/DC) and environmental temperature and humidity.
Gradually increase the voltage until breakdown occurs, record the critical voltage value, and repeat the test to take the average value.
3、 Compliance verification objectives
Security performance verification
Determine the breakdown field strength (withstand voltage per unit thickness) of insulation materials to prevent equipment from causing fires or short circuits due to insulation failure.
Detect potential defects (such as paint film pinholes, impurities) to ensure that the product has no local insulation weak points.
standard compliance
Verify complianceIEC 60851-5(enameled wire)UL 1449Access requirements for industries such as electrical equipment.
Through accelerated aging testing (high temperature)/Simulate long-term use scenarios with high humidity and evaluate material durability.
4、 Typical application scenarios
enameled wireTest the limit voltage of the insulation layer (such as10kVOptimize the painting process and select qualified products (as mentioned above).
mica sheetThrough power frequency breakdown test（200kV）Verify insulation reliability in high-temperature environments.
Silicon carbide（SiC）Evaluate its breakdown voltage stability in high-voltage power electronic equipment.
5、 Safety protection measures
Operating SpecificationsWear insulated gloves and goggles, maintain a safe distance to prevent arc injuries.
Equipment maintenanceRegularly calibrate instruments, manually discharge after testing to avoid residual voltage risks.
emergency responseConfigure emergency stop button and first aid equipment to ensure quick response in case of emergencies.
6、 Test report and improvement
Record the breakdown voltage, breakdown location, and environmental parameters, and analyze whether the data meets the design expectations.
By comparing the test results of different processes or materials, optimize the production process and promote technological innovation.
Through the above process, breakdown voltage testing can effectively ensure product safety and compliance, while providing scientific basis for the long-term stable operation of electrical equipment
Precautions for using voltage breakdown tester and dielectric strength tester (withstand voltage tester):
When using a voltage breakdown tester/When conducting breakdown strength tests on vulcanized rubber or other insulation materials using a dielectric strength tester (voltage tester), it is necessary to strictly comply with safety regulations and ensure the accuracy of the test results. The following is a detailed explanation of key precautions:
1、 Safety protection measures
1. High voltage hazard protection
Operators must receive safety training on high-voltage equipment and be familiar with the emergency stop button and power-off process of the equipment.
Set warning signs in the testing area (such as“High Voltage Danger”）Prohibit unrelated personnel from approaching.
The equipment must be reliably grounded (grounding resistance)≤4Ω）To avoid electric leakage or static electricity accumulation.
2. protective device
Ensure that the testing instrument is equipped with a safety interlock device (such as automatic power-off when the protective cover is not closed).
Use insulation operators (such as high-voltage insulation gloves, insulation pads) to assist in the operation.
3. Personal protective equipment（PPE）
Wear insulated gloves to avoid electric arcs or damage from flying objects.
2、 Equipment setup and calibration
1. Voltage parameter setting
Boosting rate: according to standards (such asASTM D149）Choose an appropriate speed (usually500 V/sor100 V/s）.
Initial voltage: from0Start gradually increasing the pressure to avoid sudden high voltage impact on the sample.
2. Electrode selection and installation
Use standard electrodes (such as spherical or cylindrical electrodes) that comply withIEC 60243Requirement).
Ensure that the electrode surface is flat, clean, and free of oxidation or stains (can be wiped with alcohol).
3. Calibration and Verification
Regularly calibrate equipment (voltmeter and ammeter accuracy must meet standard requirements).
Verify the accuracy of the equipment using standard samples with known breakdown voltage.
3、 Sample processing and testing conditions
1. sample preparation
The sample thickness is uniform (usually1-3 mm）No bubbles, impurities or mechanical damage.
Clean and dry the surface (avoid hand sweat, dust, or grease contamination).
2. environmental control
temperature23±2℃Humidity:50±5% RH(Refer to standard requirements).
Avoid electromagnetic interference (stay away from power equipment or high-frequency signal sources).
3. Sample fixation and contact
Ensure that the sample is in close contact with the electrode to avoid partial discharge caused by air gaps.
Slight pressure can be applied to soft rubber samples (such as1 N）Ensure a snug fit.
4、 Test process operation specifications
1. Gradually increase the voltage
Slowly increase the voltage to avoid misjudging the breakdown point due to sudden voltage changes.
Real time monitoring of current (sudden increase in current at breakdown moment).
2. Breakdown determination
Breakdown standard: When the current exceeds the set threshold (such as5 mA）Or the sample may undergo carbonization or perforation.
At least test the same sample at different positions3Next, take the average (excluding outliers).
3. data recording
Record the breakdown voltage, sample thickness, environmental conditions, and breakdown mode (such as surface discharge or through breakdown).
5、 Post test processing and maintenance
1. Residual charge release
●Dual system interlocking technology and isolation shielding technology:
Application of dual system interlocking technology in electrical breakdown instruments,The voltage breakdown instruments produced are equipped with overvoltage and overcurrent protection systems,it*The dual system interlocking mechanism,When any component has a problem or a single system malfunctions,Instantly cut off the high voltage.
Beiguang Product Warranty and After sales Service Commitment:
1、 Installation and commissioning: Assist in the installation of the testing machine, responsible for the transportation and commissioning of the testing machine.
2、 Acceptance criteria: The testing machine shall be accepted according to the ordered technical attachments. The final acceptance shall be conducted by the buyer, who shall test the samples provided by the user and provide a test report.
3、 Training: During installation and debugging, provide one-time free training for operators at the instrument operation site2-3The operator should be a long-term and stable employee selected by the demand side. After training, they should be able to understand and apply the basic principles, software usage, operation, and maintenance of the equipment, enabling them to independently operate the equipment for sample testing and analysis, as well as perform basic maintenance.
4、 Software upgrade: Free lifetime provision of new version control software.
5、 Warranty:1The equipment comes with a two-year warranty and lifetime after-sales service. Parts that are not damaged by human factors will be replaced free of charge within one year. After receiving an invitation from the user during the warranty period, the delayed response time is2Within hours, after confirming the fault with the user, our company will48Send engineers to the site within hours for free service, quickly identify the location and cause of the fault, and promptly report the cause and troubleshooting methods to the user.
2During the warranty period, parts damaged by human factors will be replaced at the purchase (processing) price.
3Continue to provide high-quality technical services to users beyond the warranty period, and upon receiving a repair invitation from the user3Send engineers to the user's site within the day for maintenance. And enjoy preferential treatment for purchasing spare parts.
4Overloading of sensors and damage to the overall circuit caused by overvoltage are not covered by the warranty.
6、 After sales management:
Our company implements computerized management, implements a regular telephone follow-up system for customers, regularly reviews the working condition of equipment, provides regular telephone guidance to users on equipment maintenance and testing to ensure normal operation, tracks customer equipment usage, and enables timely maintenance of equipment
Safety protection measures for voltage breakdown tester: Company profile
Beijing Beiguang Precision Instrument Company is a high-tech enterprise specializing in the production of testing instruments and automation equipment, with modern design and development technology and advanced production equipment. Actively focusing on the production and development of a variety of high-performance testing equipment and non-standard automation equipment, the main R&D and production products: insulation material testing instruments (voltage breakdown tester, resistivity tester, dielectric constant tester, leakage tracking tester, arc resistance tester, etc.), sponge foam testing instruments (ball drop rebound tester, compression deformation tester, indentation hardness tester, fatigue impact tester), mechanical equipment (universal tester) and other quality has reached the standard.
GB/T 1981. 2-2003Paint for Electrical Insulation2Part: Test Methods（IEC 60464“2: 2001, IDT)
GB/T 7113. 2-2005Insulated hose Test method（IEC 60684-2:1997 ,MOD)
GB/T 10580-2003Standard conditions used for solid insulation materials before and during testing(IEC 60212: 1971,IDT) ISO 293: 1986plastic Thermoplastic material compression molded specimens
ISO 294-1: 1996plastic Injection molding method for thermoplastic material specimens 第1part: General principles, multi-purpose molded parts and strip specimens
ISO 294-3: 1996Plastic Science Injection molding method for thermoplastic material specimens 第3Part: Small board ISO 295: 1991plastic Thermosetting material compression molded specimen
ISO 10724: 1994plastic Thermosetting molding compound Multi purpose injection molded specimens
IEC 60296: 2003Specification for unused mineral insulating oils for transformers and switches
IEC 60455-2, 1998Orange resin based reactive composite for electrical insulation 第2Part: Test Methods IEC 60674-2: 1988Plastic film for electrical purposes 第2Partial test methods: When the electrical breakdown test sample is subjected to electrical stress, its insulation performance is severely lost, and the resulting test field current causes the corresponding circuit breaker to operate. Note: Breakdown is usually caused by partial discharge in the gas or liquid medium around the electrode during the test, and the sample at the edge of the smaller electrode (or two equal diameter electrodes) is damaged. When the sample and the gas or liquid medium around the electrode are subjected to electrical stress, their insulation performance is lost, and the resulting test circuit current causes the corresponding circuit breaker to operate. Note: The appearance of carbide channels or penetration of the sample can be used to distinguish whether the test is breakdown or flashover. breakdown voltage<In the continuous boost test>The voltage at which the sample experiences breakdown under specified test conditions.<In the step-by-step boosting test>The high voltage that the sample can withstand means that at this voltage level, the sample does not experience breakdown throughout the entire time. The electrical strength is the quotient of the breakdown voltage and the distance between the two electrodes to which the voltage is applied under specified test conditions. Unless otherwise specified, this section should be followed5.4Specify the distance between two test electrodes for measurement. The significance of the experiment is that the electrical strength test results obtained in this section can be used to detect changes or deviations in performance relative to normal values caused by process changes, aging conditions, or other manufacturing or environmental conditions, and are rarely used to directly determine the performance status of insulation materials in practical applications. The electrical strength test values of materials can be influenced by various factors such as the state of the samplea)The thickness and uniformity of the sample, and the presence of mechanical stress;b)Sample pretreatment, especially drying and impregnation processes;c)Whether there are pores, moisture, or other impurities present. Test conditionsa)The frequency, shape, and rate or duration of voltage application;b)Environmental temperature, air pressure, and humidity;c)Electrode shape, electrode size, and thermal conductivity;d)The electrical and thermal characteristics of the surrounding medium. When studying new materials without practical experience, all these influential factors should be taken into account. This section specifies some specific conditions for quickly distinguishing materials and can be used for quality control and similar purposes. The results obtained by different methods cannot be directly compared, but each result can provide information about the electrical strength of the material. It should be pointed out that the electrical strength of some materials decreases with the increase of sample thickness between electrodes, and also decreases with the increase of voltage application time. Due to the significant impact of the strength and duration of surface discharge before breakdown on the electrical strength measured by most materials, in order to design electrical equipment with no partial discharge until the test voltage, it is necessary to know the electrical strength of the material without discharge before breakdown. However, the methods in this section are usually not applicable for providing information in this regard. Materials with high electrical strength may not be able to withstand long-term degradation processes, such as thermal aging corrosion, chemical corrosion caused by partial discharge, electrochemical corrosion under humid conditions, or electrochemical corrosion under humid conditions, all of which can lead to damage during operation at lower electric field strengths. The electrodes and sample metal electrodes should always be kept smooth, clean, and defect free. note1When testing thin specimens, electrode maintenance is particularly important. In order to minimize electrode damage during breakdown, stainless steel electrodes are preferred. The wire connected to the electrode should neither tilt or move the electrode, nor cause pressure changes on the specimen, nor significantly affect the electric field distribution around the specimen2Test very thin films (e.g.<5μmthick>At that time, the product standards for these materials should specify the electrodes used, the operating procedures, and the preparation methods of the specimens. The test planting materials and sheet materials (including paper planting, paper, fabric, and film) with unequal diameters perpendicular to the surface of non laminated materials and perpendicular to the layer direction of laminated materials are composed of two metal cylinders with rounded edges to a radius of（3.0soil0.2) mmThe arc. The diameter of one of the electrodes is（25scholar1) mm, Gao Yue25 mmThe diameter of the other electrode is（75Shi.mm, Gao Yue 15 mm. Two electrodes placed with uranium, with an error of 2mmInside, as shown in the picturela）As shown.1Insulation samples subjected to high and low temperature air breakdown, voltage withstand test or step test;Insulation samples subjected to high and low temperature immersion in oil for breakdown, withstand voltage test or step test;Insulation sample air breakdown, withstand voltage test or step test;Insulation sample immersed in oil for breakdown, withstand voltage test or step test;
The program test should record the following contents:
a)Subject sample;
b)Measurement method for sample thickness (if not the nominal thickness);
c)Preparation before the experiment;
d)Number of samples (if not)5One, it should be noted);
e)Test temperature;
f)Surrounding media;
g)The electrodes used;
h)Boosting method;
Report the results based on electrical strength or breakdown voltage. Will comply with the5The electrode of the seal should be installed on the sample, and precautions should be taken to prevent damage to the sample when installing the electrode. Use in accordance with clause8Zhang's electrical equipment applies voltage between two electrodes and connects them10. 1to10. 5One method is to increase the voltage and observe whether the sample is breakdown or flashover<See Section11chapter>Boosting method short-term<Run fast>experiment Start the test voltage from zero and increase it uniformly until breakdown occurs. When selecting the opening speed for the test material, the majority of breakdown should occur at(10～20) sbetween. Significant impact on breakdown voltage Different materials may also be damaged outside of this time range If most breakdowns occur in(10～20) sBetween them, it is considered that the experiment was successful. The boosting speed should be selected from the following:100V/s,200 V/s, 500V/s，1000 V/s，2000v /s, 5000v /sWait a minute. Note: For most materials, it is usually used500 V/sThe boost speed is recommended for molding materials2 000 V/sBoosting speed to obtain andIEC 6029 6, 2003Comparable data that is suitable.
20sStep by step voltage boosting test Translate into English40%The expected short-term breakdown voltage is applied to the trial mix. If the expected value of short-term breakdown voltage is unknown, it should be calculated according to10. 1The method to obtain it. If the sample can withstand this voltage20 sIf it has not yet penetrated, it should be done according to the table1The prescribed increment gradually increases the voltage. Each increase in voltage should be applied immediately and continuously20sUntil breakdown occurs. The boost should be as fast as possible without any transient overvoltage, and the time used for inter stage boost should be included in the higher stage voltage20 sDuring the period. If the breakdown occurs less than from the beginning of the test6Within the voltage range of the level, use a lower starting voltage before proceeding5Testing of individual samples. According to the tolerance of the sample20sAnd high test electricity without breakdown is used to determine electrical strength. Slow boost test（120～240) sfrom40%The expected short-term breakdown voltage starts to steadily increase, causing breakdown to occur(120～240) sbetween. For materials with significant differences in breakdown voltage, some samples may experience damage outside of this time range, If most breakdowns occur in(120～240) sBetween them, it is considered satisfactory. When selecting the boost speed, one should start from the following data:2 /sVSon,5 V/s,10 V/s,20 V/s, 50 V/s,100 V/s,200 V/s,500 V/s,l 000 V/sWait a minute. 60sUnless otherwise specified, the logic boost test should be conducted according to10. 2Conduct experiments, but the withstand voltage time in each level is60 s,Extremely slow boost test（300～600) sUnless otherwise specified, according to10.3Conduct experiments, but breakdown should occur at（300～600) sbetween. Select the boost speed from the following data:1V/s,2 VSon,5 V/s,10 V/s,20 VSon,50 V/s,100 V/s,200 V/sWait a minute.
note:in10.3As described in(120～240) sThe slow boost test and in10.5As described in（300～600) sThe results of the extremely slow boost test and20 sStep by step voltage increase(10, 2）Or60 sStep by step voltage increase(10, 4）The results obtained are similar When using modern automatic equipment, the first two are more convenient than step-by-step voltage boosting tests, and the use of these two slow opening voltage tests also makes the use of automatic equipment possible.When conducting an inspection or voltage withstand test, it is required to apply a predetermined voltage value. Raise the voltage as quickly and accurately as possible to the required value, without any transient overvoltage during the boosting process. Then maintain the required voltage value for the specified time. The determination of breakdown involves an increase in current in the circuit and a decrease in voltage across the sample during electrical breakdown. The increase in current can cause the circuit breaker to trip or the fuse to burn out. However, sometimes it can also cause the circuit breaker to trip due to flashover, sample charging current, leakage or local current, equipment magnetization current, or misoperation. Therefore, the circuit breaker should match the characteristics of the testing equipment and the tested material. Otherwise, the circuit breaker may act before the sample breaks down or not act when the sample breaks down, making it difficult to correctly determine whether it has broken down. Even under certain conditions, there may still be situations where the surrounding medium breaks down first. Therefore, during the testing process, attention should be paid to observing and detecting these phenomena. If medium breakdown is found, it should be noted in the report. Note: For materials that are particularly sensitive to leakage detection circuits, the same explanation should also be provided in the standards for such materials. When tested perpendicular to the material surface, it is usually easy to determine whether the channel is filled with carbon particles or not. After breakdown occurs, the true breakdown channel can be easily seen with the naked eye. When tested parallel to the material surface, it is required to determine whether the breakdown phenomenon is caused by sample failure or failure caused by flashover (see5.2）. Identification can be made by inspecting the sample or applying another voltage, and the value of the applied voltage should be less than the specified value The breakdown voltage value applied once. The experiment proves that the voltage value applied again is equivalent to the breakdown voltage value50%More suitable, then use Use the same method as in the second experiment to increase the pressure until it is destroyed. Unless otherwise specified, the number of tests should usually be conducted5For the second experiment, take the median of the test results as the value of electrical strength or breakdown voltage. If any test result When the experiment is not used for routine quality control, a large number of samples must be made, and the quantity of samples is related to the dispersion of the material and the statistical analysis method used. For quality control tests that are not intended for routine use, please refer to the appendixAIt is useful for determining the required number of experiments and data analysis references.
Unless otherwise specified, the report shall include the following contents
a)Full name of the tested material, description of the sample and its preparation method for the voltage breakdown strength tester (voltage breakdown tester);
b)Voltage breakdown strength tester (voltage breakdown tester) for the median electrical strength<withkV/mmexpress>Or the median breakdown voltage (askVRepresentation);
c)Voltage breakdown strength tester (voltage breakdown tester) for measuring the thickness of each sample<see5.4)；
d)The surrounding media and their properties used during the experiment;
e)Electrode system;
f)The method and frequency of applying voltage;
g)Various values of electrical strength (in terms ofkV/mmexpress>Or various values of breakdown voltage<withkVRepresentation);
h)The temperature, pressure, and humidity when tested in air or other gases, and the temperature of the surrounding medium when tested in liquid;
i)Pre experimental condition treatment;
j）Explanation of breakdown type and location.
If only a simple result report is needed, it should be reported before6Item content and low and high values.
Instrument advantages:
1Automatic discharge;
2AC voltage, DC voltage, and current testing errors1%；
3The electrode bracket is made of high-quality epoxy board;
4The software is capable of continuous operation10Comparison of group experiments;
5Different colors of experimental curves can be overlaid for comparison;
6The software can set current protection function;
7Equipped with a host control area, the host can be controlled independently without a computer;
8The host has voltage and current display functions;
9Built in exhaust system;
10Built in lighting function;
11Discharge alarm device;
12Bluetooth remote control;
13Three color light alarm device (green light box door closed well, yellow light open door with caution, red light has high voltage);
14Can achieve dual operation of touch screen or computer;
15Combination programming can be implemented, and the boost and withstand times of gradient boosting can be set separately;
16TheUDisk download function, which can directly download the test records from the device toUIn the plate.
Instrument features:
1Independent control system, modular structure for easy after-sales maintenance, beautiful appearance, no noise during the entire experimental process, automatic centering and positioning of the electrical level, easy operation, high safety factor, and accuracy.
2The operation and control are carried out by the touch screen and control panel of the device itself. If curve analysis is not required, a computer is not required.
3If curve analysis is required, a computer can be equipped to only perform data and curve recording functions without equipment control, avoiding the need for testers to alternate between the computer and equipment, making it more user-friendly.
4The equipment has a test parameter memory function, and it is not necessary to set the same test conditions for each test, and the parameters set for the next test will still be remembered when the power is turned off.
5The experimental interface is simple and clear, with illustrated curve explanations. Different parameters result in different curve trends, making it easy to understand.
6The control panel is simple, with clear functional labeling and easy operation.
7Can record and display simultaneously10Record the second experiment to facilitate comparative analysis of experimental data. And any set of data that is not ideal can be discarded at any time.
8AddedUDisk download function, which can directly download the test records from the device toUIn the plate.
9If equipped with a computer, a detailed test report can be generated, including information for each group, multiple sets of comprehensive information, and curves.
10The equipment testing interface adopts a dashboard and real-time display of numbers, which is more convenient for viewing the testing process.
11The equipment has a safety warning prompt. The test cannot start without closing the test box door, and a warning will pop up. When it is at full capacity (i.e. no output from the high-voltage transformer), a warning will pop up. If the door is opened during the test, the test will automatically end.
12Using Bluetooth data transmission to solve the trouble of wall blocking and long-distance operation safety and reliability;
13The equipment is equipped with a three color alarm. When the green light is on, it indicates that the box door is well closed and the test can begin. When the yellow light is on, it indicates that the test box door is open and the sample can be replaced. When the red light is on, it indicates high voltage0.5KVDo not open the door at this time. The warning light will flash and sound an alarm during the discharge process after the DC test is completed. (Summary: The green light box door is closed well, the yellow light is opened with caution, and the red light has high voltage) This standard followsGB/T1.1-2009Draft the given rules. This standard is revised using the redrafting methodISO6237:2003Measurement of Tensile and Shear Strength of Adhesive Wood to Wood Bonding
Ding.
GB1408-2016 GB/T 507-2002
GB/T1695-2005 DL429.9-91
GB/T3333Measurement of breakdown voltage of insulating oil
HG/T 3330Measurement method for dielectric strength of insulating oil
GB12656 ASTM D149.
Main functions:
1During the experiment, the test curve can be dynamically drawn, and the test curve can be overlaid with multiple colors for comparison.
2Can edit and modify experimental data, flexible and applicable;
3Data such as experimental conditions and test results can be automatically stored;
4The format of the test report is flexible and adaptable to meet the different needs of different users;
5The validity of curve data in a set of experiments can be manually selected;
6The experimental result data can be importedEXECL,WORDDocument editing;
7The overcurrent protection device has sufficient sensitivity to ensure that the sample can withstand breakdown0.1SCut off the power supply internally;
8Durability of instrument operation:The instrument can operate continuously without the need for regular shutdowns to protect it.
9The software can set the administrator and each user's own parameters and report storage permissions.Test method for tensile shear strength of wood adhesives
ASTM D149This standard is applicable to the determination of breakdown strength of insulation paint film,Under certain conditions,Apply AC voltage to the paint film continuously and uniformly until breakdown occurs,The ratio of breakdown voltage value to paint film thickness is the breakdown strengthE,In kilovolts/Millimeter representation,GB 12656-1990.Determination of electric strength at power trequence for capacitor paper. GB 12656Reference adoptedIEC 243- 1(1988)Test Method for Electrical Strength of Solid Insulation Materials. 1Theme content Scope of application GB 12656The method for measuring the breakdown voltage of capacitor paper under power frequency is specified. GB 12656Suitable for non impregnated capacitor paper or other similar materials. 2Reference standards GB450Sampling of paper and cardboard samples GB 1408Solid insulation material power frequency Test method for gas strength 3definition 3.1breakdown voltagebreakdown voltageUnder the specified experimental conditions,Apply processing frequency voltage to capacitor paper using continuous and uniform voltage boosting method,The voltage value at which the paper pattern breaks down. 3.2electric strengthelectric stengthUnder the specified experimental conditions,The voltage value at which the capacitor paper sample breaks down is divided by the average thickness of the paper sample between the two electrodes to which the voltage is applied. 4Test instrument 4.1The power frequency breakdown tester should comply withGB1408第5Regulations on Test Equipment. 4.2electrode 4.2.1electrode material For brass. 4.2.2size:Upper electrodeφ25 mm,Edge rounding radiusr=2.5 mm;Lower electrodeφ25mm,The determination of edge breakdown involves an increase in current in the circuit and a decrease in voltage across the sample during electrical breakdown. The increase in current can cause the circuit breaker to trip or the fuse to burn out. However, sometimes it can also cause the circuit breaker to trip due to flashover, sample charging current, leakage or local current, equipment magnetization current, or misoperation. Therefore, the circuit breaker should match the characteristics of the testing equipment and the tested material. Otherwise, the circuit breaker may act before the sample breaks down or not act when the sample breaks down, making it difficult to correctly determine whether it has broken down. Even under certain conditions, there may still be situations where the surrounding medium breaks down first. Therefore, during the testing process, attention should be paid to observing and detecting these phenomena. If medium breakdown is found, it should be noted in the report. Note: For materials that are particularly sensitive to leakage detection circuits, the same explanation should also be provided in the standards for such materials. When testing perpendicular to the material surface, it is usually easy to determine whether the channel is filled with carbon particles or not. After breakdown occurs, the true breakdown channel can be easily seen with the naked eye. When testing parallel to the material surface, it is required to determine whether the breakdown phenomenon is caused by sample failure or failure caused by flashover. Identification can be made by inspecting the sample or applying another voltage, and the value of the voltage applied again should be smaller than the breakdown voltage value applied once. The experiment proves that the voltage value applied again is equal to the breakdown voltage value of the younger brother50%More suitable, then use Use the same method as my younger brother's experiment to increase the pressure until it is destroyed.
Unless otherwise specified, the number of tests should usually be conducted5For the second experiment, take the median of the test results as the value of electrical strength or breakdown voltage. If any experimental result deviates from the median value15%Above, do it separately5The second experiment. And then10The median of the second test is used as the value of its electrical strength or breakdown voltage. When the test is not used for routine quality control, a large number of samples must be made, and the number of samples is related to the dispersion of the material and the statistical analysis method used. For quality control tests that are not intended for routine use, please refer to the appendixAIt is useful for determining the required number of experiments and data analysis references. Standard test method for breakdown voltage and insulation strength of solid electrical insulation materials at industrial frequencies1This standard is designated by a fixed codeD149Published. The following numbers represent the official year of adoption of the original text; In the case of revisions, use the year of the previous revision; The number in parentheses represents the year of the last reconfirmation. Superscript symbol（ε）Indicates that there have been editorial changes made to the last modified or re determined version.
This standard has been approved for adoption by the Ministry of National Defense agencies. The scope of the voltage breakdown tester covers the process of measuring the insulation strength of solid insulation materials under specific conditions at industrial frequencies. Unless otherwise specified, the specified frequency for this test is60HHowever, this testing method can also be applied to25to800HUnder the given conditions. If the frequency is800HSo there will be a problem of medium heating.This testing method will be compared with other methodsASTMUse standards or other standards related to the test method in combination. The references of this method will provide a detailed explanation of the volume standards used. This method can be applied to various temperatures and suitable gas or liquid environment media. This method cannot be used to determine insulation materials that are liquid under the test conditions. This method cannot be used to determine intrinsic insulation strength, DC insulation strength, or thermal failure under electrical stress conditions. This testing method is commonly used to determine the relationship between breakdown voltage and sample thickness (breakdown). It can also determine the relationship between breakdown voltage and the surface condition of solid samples, as well as the gas or liquid phase environment medium (flashover). If the modification instructions are added, this testing method can still be used for validation experiments. This testing method is in accordance with the International Electrotechnical Association（IEC)Published by243-1The standards are similar. All processes in this method are included inIEC 243-1In the standard. This method andIEC 243-1Mainly there are differences in editing. This standard does not list all safety statements. If necessary, it should be considered based on actual usage. Before using this specification, the user is responsible for formulating regulations and specifications that comply with safety and health requirements, and clarifying the scope of use of this specification. The harm to the body will be in the7Partially elaborated.ASTM D149-2009Dielectric breakdown voltage test method - Voltage withstand breakdown tester2. Reference documentASTMStandard:D374Testing method for thickness of solid electrical insulators（2013Annual cancellation)D618Operating procedures for adjusting plastics used in experimentsD877Test method for determining the dielectric breakdown voltage of insulating liquids using a disk electrode
D1711Terminology related to electrical insulationD2413Preparation procedure for insulating paper and paperboard impregnated with liquid mediumD3151Test method for thermal failure of solid electrical insulation materials under electrical stress（2007Annual cancellation)5D3487Standard specification for mineral insulating oil used in electrical equipmentD5423The electrical insulation evaluation specification for forced convection test furnaces applies to insulation materials such as rubber, plastic, film, ceramic, glass, paint film, resin, wire and cable, insulation oil, etc
Test items: breakdown voltage test, dielectric strength test, electrical strength test, withstand voltage breakdown strength test, etc
IECStandard publications243-1Test method for dielectric strength of solid insulation materials—第1Part: Testing at industrial frequencies6
ANSIStandard insulation testing techniques,IEEEStandard Number47
1This experimental method is used inASTMcommitteeD09Within the jurisdiction of electronic and electrical insulation materials,D09.12The branch (electrical testing) is directly responsible.
This version is2013year4moon1The day was approved,2013year4Monthly publication. The first edition1922Year approved. The previous version wasD149-09Yu2009Year approved.DOI:10.1520/D0149-09R13.
For the referenceASTMstandard
ASTM D149-2009Test method for dielectric breakdown voltage
Voltage breakdown tester3. term
3.1Definition:
Dielectric breakdown voltage (breakdown voltage), noun: the potential difference that causes an insulating material located between two electrodes to lose its dielectric properties. Discussion on dielectric breakdown voltage, sometimes abbreviated as“breakdown voltage”Dielectric failure (in testing), noun: refers to the situation that can be sustained by an increase in dielectric conductivity under the limited electric field conditions of the test. Insulation strength, noun: refers to the voltage gradient that causes dielectric failure of insulation materials under specific testing conditions. Electrical strength, noun: see insulation strength. Discuss internationally,“electric strength”More commonly used. Flashover, noun: refers to a destructive electrical spark that occurs in an insulator or surrounding medium, without necessarily causing damage to the insulator. The definitions of other terms related to solid insulator materials and the summary of testing methods for voltage breakdown tester under industrial electrical frequency conditions (unless otherwise specified)60H）Apply different voltages to the test samples. Using one of the three methods described by voltage, change the voltage from0Or start from an appropriate voltage lower than the breakdown voltage and raise it until dielectric failure occurs in the test sample. In most cases, simple test electrodes are installed on both sides of the test sample for voltage testing. The test samples can be molded, cast, or cut from flat sheets or thick plates. Other electrodes or sample structures can also be used to adapt to the geometric shape of the sample material, or to simulate the specific use of the material being evaluatedASTM D149-2009Test method for dielectric breakdown voltage. The significance of the voltage breakdown tester and the insulation strength of the electrical insulation used determine the key performance of the material under what conditions it can be used. In many cases, the insulation strength of materials is a decisive factor in the design of the devices used. The tests introduced in this method will be used to provide some necessary information to determine the suitability of the material under certain application conditions; Of course, it can also be used to detect changes or deviations from normal characteristics caused by changes in processes, degree of aging, or other manufacturing or environmental conditions. This testing method can be effectively applied to process control, validation, or research testing. The results obtained from this testing method are rarely directly applicable for determining the dielectric properties of materials in practical use. In most cases, other functional tests and/Alternatively, the results obtained from material testing can be compared to estimate their impact on specific materials before evaluation can be conducted. Three voltage usage methods are described. methodAQuick testing; methodBStep by step testing; methodCSlow testing. methodACommonly used for quality control testing. A more time-consuming methodBandCUsually give lower results, but when comparing different materials, their results are more convincing. If an electric voltage controller can be installed, the slow testing method will be simpler and more commonly used than the step-by-step testing method. methodBandCThe results obtained can be compared with each other. Measurement method for power frequency breakdown voltage of capacitor paper
GB 12656-90This standard is referenced and adoptedIEC243-1(1988)(Test method for electrical strength of solid insulation materials).
This standard specifies the method for measuring the breakdown voltage of capacitor paper under power frequency. This standard applies to non impregnated capacitor paper or other similar materials.
Reference standardsGB450Sampling of paper and cardboard samplesGB 1408Test method for power frequency electrical strength of solid insulation materials
Define breakdown voltagebreakdown voltageUnder the specified experimental conditions,Apply processing frequency voltage to capacitor paper using continuous and uniform voltage boosting method,Voltage at which the paper pattern breaks down
Value.
electric strengthelectric sttengthUnder the specified experimental conditions,The voltage value at which the capacitor paper sample breaks down is divided by the average thickness of the paper sample between the two electrodes to which the voltage is applied
Degree.
The power frequency breakdown tester of the experimental instrument should comply withGB 1408第5Regulations on experimental equipment,
The electrode material of the electric plate is brass, and the size is suitable for television625mm,Edge inverted radius+m2.5mm;Lower electrode425 mm,Edge rounding radiusr-2.5 mmors30~40 mms≠75 mm1
Applicable test method standards
1TheGB/T1695-2005Determination method for power frequency breakdown voltage strength and withstand voltage of vulcanized rubber
2TheGB/T3333Test Method for Power Frequency Breakdown Voltage of Cable Paper
3TheGB12913-2008Capacitor paper
4TheASTM D149Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulation Materials at Industrial Power Supply Frequency
Glass product voltage breakdown tester
Mainly suitable for testing the breakdown strength and withstand time of solid insulation materials such as wire sleeves, resins and adhesives, impregnated fiber products, mica and its products, plastics, film composite products, ceramics and glass under power frequency voltage or DC voltage; This instrument is computer-controlled and can quickly and accurately collect, process, access, display, and print various data during the experimental process
Rubber and plastic power frequency withstand voltage dielectric breakdown strength tester breakdown voltage(V)Apply a continuous and uniform voltage boost to the sample while maintaining the voltage value at which breakdown occurskVexpress. Breakdown strength(E)The quotient of the breakdown voltage value of the sample and the average thickness of the sample between the two electrodes, denoted askV/mm.
Installation of rubber and plastic power frequency withstand voltage dielectric breakdown strength tester instrument
The instrument is installed on a horizontal cement floor with no vibration or corrosion space. It is recommended to keep a distance from the wall and the operator1Above meters.
There is a high-voltage transformer at the rear of the instrument with a quality deviation. Please pay attention during transportation and installation.
This instrument is recommended to be lifted in place at once, and for forklift installation, it is recommended to install it with two front and rear units in coordination. Power terminal wiringABCfor220VThree phase, the ground wire must be connected to the neutral wire
The grounding terminal must be well grounded with multiple strands of copper wire.
Please do not connect the high voltage reserve and low voltage reserve, and prepare special tests for high voltage external connection.
The high-voltage and low-voltage insulation columns can suspend the high-voltage leads when not in use for a long time or when replacing external high-voltage and other operators to avoid misoperation.
During the experiment, the high and low voltage lead ends are connected using high voltage lead alligator clips and low voltage lead alligator clips.
Under normal circumstances, high voltage clicks and low voltage electrodes are25mmand75mmTwo smooth copper electrodes with circular surfaces are fixed with screws at the upper and lower parts. If replacement is necessary in special circumstances, please unscrew the corresponding screws and replace the spare electrodes in the attachment.
The fixing point of the oil box is a protruding pin that can lift the oil box vertically upwards, remove and place it, making it easy to replace transformer oil.
The oil box bracket is an integral electric wood mechanism that can be easily removed and replaced with electrodes.
The addition of transformer oil should be less than the upper part of the upper electrode30mm.
Glass product voltage breakdown tester
1、 Manufacturing and inspection standards for products
1TheGB1408.1-2006Test Method for Electrical Strength of Insulation Materials
2TheGB1408.2-2006Test Method for Electrical Strength of Insulation Materials 第2Part: Additional Requirements for Application of DC Voltage Test
3TheJJG 795-2004Verification Regulations for Voltage Endurance Testers
2、 Application scope
Mainly suitable for testing the breakdown strength and withstand time of solid insulation materials such as wire sleeves, resins and adhesives, impregnated fiber products, mica and its products, plastics, film composite products, ceramics and glass under power frequency voltage or DC voltage; This instrument is computer-controlled and can quickly and accurately collect, process, access, display, and print various data during the experimental process.
3、 Applicable test method standards
1TheGB/T1695-2005Determination method for power frequency breakdown voltage strength and withstand voltage of vulcanized rubber
2TheGB/T3333Test Method for Power Frequency Breakdown Voltage of Cable Paper
3TheGB12913-2008Capacitor paper
4TheASTM D149Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulation Materials at Industrial Power Supply Frequency
Glass product voltage breakdown tester
Technical Requirements
01Input voltage: communication 220 V
02Output voltage: communication/direct current 0--50 KV ;
03Electrical capacity:2KAV 3KAV 5KAV 10KVA
04High voltage classification: 0-10KV 0--50KV 0--150KV
05Boosting rate:0.01-5.0kv(arbitrary)
06Test method: Delivery/DC test:1Constant speed boosting 2Gradient Boosting 3Voltage withstand test
07Test medium: Air
08Support short circuit test requirements in a short period of time.
10Voltage test accuracy: ≤ 1%.
11Continuous adjustable test voltage: 0--100 KV.
12Current can be collectedmAnd achieve Real time collection.
13Provide a calibration certificate for first level measurement units or a certificate for customer measurement units
14Power supply:220v±10%Single phase AC voltage and50H±1%The frequency
15Current and voltage stability: external voltage fluctuations10%(Optional to be equipped with our company's voltage protector) Rated fluctuation voltage30%）
16Boosting device: using advanced contactless components to uniformly boost voltage, eliminating the previous mechanical voltage regulation
17Voltage endurance time:0-7HMaintain relative voltage (software setting)
18Breakdown sample: breakdown point of the sample Small adjustability is generally1-5mm左右
19Install a highly sensitive overcurrent protection device to ensure that the sample can withstand breakdown0.05SCut off the power supply internally.
20The instrument is equipped with an advanced fault alarm system Prevent users from operating faulty instruments and causing danger
5、 Computer systems and software packages
The experimental software is a newly developed experimental software system by our company, which has strong functions, simple operation, and intuitive display.
This instrument adopts computer control and human-machine dialogue to complete the power frequency voltage breakdown and power frequency withstand voltage test of insulation media. This instrument belongs to our company and is our product,1During the experiment, the test curve can be dynamically drawn, and the test curve can be overlaid with multiple colors for comparison. It can be placed locally, and any section of the curve can be analyzed for regional placement;
2Can edit and modify experimental data, flexible and applicable;
3Data such as experimental conditions and test results can be automatically stored;
4The format of the test report is flexible and adaptable to meet the different needs of different users;
5The validity of curve data in a set of experiments can be manually selected;
6The experimental result data can be importedEXECL,WORDDocument editing;
7The software equipment personnel management function allows test personnel to set their own test items and parameters. After setting their own test content, others cannot enter the program;
8The overcurrent protection device has sufficient sensitivity to ensure that the sample can withstand breakdown0.1SCut off the power supply internally;
9Durability of instrument operation:The instrument can operate continuously without the need for regular shutdowns to protect it.
6、 Safety instructions for high-voltage breakdown equipment:
1The equipment should be equipped with a separate protective grounding wire. Grounding protection is mainly used to reduce the strong electromagnetic interference caused by the breakdown of the sample to the surrounding area. It can also prevent the computer from losing control.
2DC test discharge alarm function:When the device completes the DC test,When the test door is opened, the equipment will automatically sound an alarm,The alarm will automatically cancel after the discharge device on the equipment is used to discharge.(Note: Failure to discharge electricity after DC testing may pose a risk to personal safety,Cannot directly take the electrode,Remind users to discharge to avoid personal injury).
3The experimental discharge device is integrated with the main unit, improving the previous function of having a separate discharge pole.
4The circuit of the test equipment is equipped with multiple protection measures, mainly including overcurrent protection, voltage loss protection, leakage protection, short circuit protection, DC test discharge alarm, etc.
5Level 6 high-voltage safety power-off control:
①main power switch
②High voltage power-off switch (key switch)
③Voltage regulator reset switch
④Test box door safety switch
⑤High voltage transformer input side current limiting circuit breaker
⑥Leakage protection switch
7、 Protection function
There are comprehensive security measures in place:
Circuit protection control: voltage automatically returns to zero after tripping
aOverpressure protection
bTest overcurrent protection
cTest short-circuit protection
dSafety test door protection
eSoftware misoperation protection
fZero voltage reset protection
gTest leakage protection
hGrounding protection
iDischarge protection after the end of the experiment
jEquipment malfunction alarm protection
8、 Electrode:
Electrode specifications: meetGB/T 1408.1-2006Standard requirement (material is brass)
1Sheet electrode ￠25mmtwo Sheet electrode ￠75mmone (Standard)
2Enamel wire electrode Two (optional)
3Tube electrode Two (optional)
How to choose suitable test electrodes:
There are many specifications for testing electrodes, and different electrode sizes are selected for different materials and specifications. The body is tested according to the testing standards required for the material. If there are no special requirements in the standards, the testing electrodes usually used for testing sheet materials are equal diameter and unequal diameter electrodes.
Whole machine composition1Step up component: composed of a voltage regulator and a high-voltage transformer0～50KVThe boosting part.2Moving parts: The voltage regulator is uniformly adjusted by a stepper motor to change the voltage applied to the high-voltage transformer.3Testing component: a measurement circuit composed of integrated circuits. Transmit the detected analog signal and switch signal to the computer through the signal line.4Computer software: The measurement and control signals collected by the detection equipment are transmitted to the computer through intelligent circuits. The computer controls the operation of the equipment and processes the test results based on the collected information.5Test electrode: According to the standard(1408.1-2006)Three electrodes are provided with the device, and the body specifications are:Ф25mm×25mmTwo;Ф75mm×25mmOne.
Ф25mm×25mmTwo;Ф75mm×25mmOne.
Operation steps:
1Preparation before the experiment:
1）Turn on the main power switch on the right side of the testing machine,preheat15minute
2）Open the computer and enterWindowsSystem. Double click the shortcut icon of this instrument software to open the test login interface, enter the login password to enter the test interface.
1）The high voltage output of this instrument is AC voltage.
2）Front panel DC/AC selection button.
3）The switching of AC/DC voltage in the experiment mainly depends on whether the short-circuit rod in the high-voltage insulation tower is removed.
4）In DC testing, the computer should also choose the DC state, otherwise the measured results will be incorrect.
Product advantages:
SiemenscpuUnit processor is currently a high-precision and stable acquisition system
(Eliminated the initial ones)51Single chip microcontroller control with poor acquisition accuracy and multiple interference signals and PLCThe cable is relatively long, especiallyDAWhen the module uses voltage signal output, there is a significant voltage drop in the circuit, which affects the stability and reliability of the systemCPUWidely used in communication equipment servers in China For example: China Unicom, China Mobile In terms of professional signal processing purposes, wireless Bluetooth control is more convenient for human-machine separation due to distance constraints. Get rid of the slow signal propagation caused by long data lines The problem of command delay It is precisely because of wireless Bluetooth that our instruments have features such as supporting more computers to operate simultaneously.
The automatic alarm system for instrument malfunctions provides greater safety assurance for operators.
When there is a fault in the circuit, the instrument will automatically sound an alarm to better protect personnel safety This alarm system is not related to fault alarm, test discharge alarm, or software alarm, and is equipped with network port sharing function Enable more personnel to operate the experimental results and store them on the office computer to make the report clearer and simpler (the principle is as convenient as sharing a printer)
Operating interface: Observant users can see from the experimental software diagram The difference between real-time current collection and other manufacturers is that our electrical breakdown instrument can accurately collect real-time current and draw curves. Other manufacturers cannot achieve current drawing curve collection due to poor collection accuracy
control function
1.The device can dynamically draw test curves during the testing process, and the test curves can be overlaid and compared with multiple colors.
2.Can edit and modify experimental data, flexible and applicable;
3.The experimental conditions and test results can be automatically stored as data;
4.The format of the test report is flexible and adaptable, suitable for different requirements of different users.
5.The validity of curve data in a set of experiments can be manually selected.
6.The experimental result data can be importedEXECL.
7. The software equipment personnel management function allows test personnel to set their own test items and parameters, and after setting their own test content, others cannot enter.
Definition of thin film voltage breakdown tester:
Electrical breakdown: When subjected to electrical stress, the insulation performance of the sample is severely damaged, causing the test circuit current to trigger the corresponding circuit breaker to operate.
Breakdown is usually caused by partial discharge in the gas or liquid coal surrounding the pattern and electrode, resulting in damage to the pattern of the smaller electrode or the edges of the two equal diameter electrodes.
Flashover: When the gas or liquid coal around the electrode is subjected to electrical stress, its insulation performance is lost, and the resulting test circuit current causes the corresponding circuit breaker to operate.
The appearance of carbide channels or the breakdown of penetration patterns can be used to distinguish whether the test is breakdown or flashover.
Breakdown voltage: The voltage at which breakdown occurs in a continuous boost test under specified test conditions.
The high voltage that the pattern can withstand does not cause breakdown throughout the entire time at that voltage level.
Electrical strength: The quotient of the breakdown voltage and the distance between the two electrodes to which the voltage is applied under specified test conditions.
The obtained electrical strength test results. It can be used to detect changes or deviations in performance relative to normal values caused by process changes, aging conditions, or other manufacturing environmental conditions, and is rarely used to directly determine the performance status of insulation materials in practical applications.
The electrical strength test values of materials can be influenced by multiple factors, including:;
The state of the style
aThe thickness and uniformity of the style, and whether there is mechanical stress;
bPre treatment of the style, especially the drying and soaking process
cThere are gaps in every situation. Moisture or other impurities.
Condition for Style:
aThe frequency, waveform, and boost speed or time of applying voltage
bEnvironmental temperature, air pressure, and humidity
cElectrode shape, electrode size, thermal conductivity
dThe electrical and thermal characteristics of the surrounding medium
When studying new materials without practical experience, all these influencing factors should be taken into account. The above specifies some specific conditions to quickly distinguish materials and can be used for quality control and similar purposes.
The results obtained by different methods cannot be directly compared, but each result can provide material electrical strength data. It should be pointed out that the electrical strength of most materials decreases with increasing distance between electrodes and also with increasing applied voltage.
Due to the significant impact of the strength and duration of surface discharge before breakdown on the electrical strength measured by most materials, in order to design electrical equipment without partial discharge until the test voltage, it is necessary to know the electrical strength of the material without discharge before breakdown.
Electrode and style: Metal electrodes should always be kept smooth, clean, and defect free.
Beiguang Company independently develops a professional electrical performance tester
1 Voltage breakdown tester
BDJC10KV-150KV GB1408TheGB/T1695The
GB/T3333TheGB12656The
ASTM D149
Dielectric strength, leakage current Dielectric strength, leakage current
2 Volume surface resistance tester
BEST-121 GB1410TheASTM D257The
GB/T 1692TheGB/T 2439The
GB/T 10581TheGB/T 10064
Volume resistivity, surface resistivity
LCD (Liquid Crystal Display)
3 Volume surface resistivity tester
BEST-212 GB1410TheASTM D257The
GB/T 1692TheGB/T 2439The
GB/T 10581TheGB/T 10064
Volume resistivity, surface resistivity LCD touch, electric Direct testing of resistance and electrical resistivity
4 Conductor resistivity tester BEST -19 GB11210TheGB/T15662The
GB2439TheASTM D991conductor resistivity touch screen
6 Semiconductor resistivity tester BEST-300C GB/T 1551Semiconductor resistivity touch screen
7 High frequency dielectric constant measurement
Testing equipmentGDAT--A GB1410Dielectric constant, dielectric loss test frequency 50H-
160MH
8 Power frequency dielectric constant tester BQS-37A GB1410Dielectric constant, dielectric loss test frequency 50H
9 Arc resistance tester
BDH-20KV GB1411-2002 IEC 61621
ASTMD495
Arc resistance Microcomputer control, touch screen control
10 High voltage leakage trace tester BLD-6000VHigh voltage level test Five sets of high voltage 6KV
11 Electric trace resistance index tester BLD-600V IEC60112TheASTM D 3638-92TheDIN53480Leakage traces and electrical traces CTI\\PTIhigh voltage 600V
12 Sliding friction and wear test
Testing equipmentM-200 GB3960Sliding friction and wear performance testing Friction force, friction system
Numerical curve display
Beiguang Company independently develops professional electrical performance testing instruments Voltage breakdown testerBDJC10KV-150KV GB1408GB/T1695TheGB/T3333TheGB12656TheASTM D149Dielectric strength, leakage current Dielectric strength, leakage current
Beiguang Company independently developed a professional electrical performance testing instrument, a volume surface resistance testerBEST-121 GB1410TheASTM D257GB/T 1692TheGB/T 2439TheGB/T 10581TheGB/T 10064
Volume resistivity, surface resistivity Liquid crystal display volume surface resistivity testerBEST-212 GB1410TheASTM D257TheGB/T 1692TheGB/T 2439TheGB/T 10581TheGB/T 10064
Beiguang Company independently developed a professional electrical performance testing instrument, a conductor resistivity testerBEST -19 GB11210TheGB/T15662The
GB2439TheASTM D991conductor resistivity touch screen
Beiguang Company independently developed a professional electrical performance testing instrument, a semiconductor resistivity testerBEST-300C GB/T 1551Semiconductor resistivity touch screen
Beiguang Company independently developed a professional electrical performance testing instrument, a high-frequency dielectric constant testerGDAT--A GB1410Dielectric constant, dielectric loss test frequency 50H-160MH
Beiguang Company independently developed a professional electrical performance testing instrument, a power frequency dielectric constant testerBQS-37A GB1410Dielectric constant, dielectric loss test frequency 50H
New optional features:
1. Infinite voltage regulation function: With the continuous emergence of new materials. The testing requirements for its insulation performance are constantly increasing. In the early stage, domestic testing instruments could only achieve a few fixed selectable boost speeds, which could not meet the testing needs well. After introducing the concept of stepless voltage regulation. The boost rate can be artificially set within a certain range. Can adapt well to user needs.
2. Wireless measurement and control function: In the early stage, the product was constrained by the built-in acquisition card and required a connection between the host and the computer. In order to collect data and control the host, as the host belongs to high-voltage equipment, it is inevitable to have stray electromagnetic fields. Through cable coupling, it is very easy to cause computer crashes and lose control of the host, which poses certain risks for the testing personnel. By using wireless measurement and control, human-machine separation is achieved, and the safety factor is significantly improved.
3. Automatic discharge function: After conducting a DC high voltage test, there will be a small amount of residual charge on the equalizing ball (high voltage electrode). If the electrode is directly operated at this time, there will be a momentary electric shock sensation, causing discomfort. In addition to sound and light alarms, our company's products can also automatically discharge the equalizing ball with a grounding wire when opening the experimental cabin door. Ensure safety.
4. Frequency conversion function: Due to the different environmental conditions determined by the application scenarios of insulation materials, such as motors working under the drive of frequency converters, how to truly simulate working conditions has become a problem facing users. Our company's products can better meet the needs of customers. The output voltage frequency can vary between tens of hertz and 400 hertz, and the testing methods can be divided into constant voltage variable frequency and constant frequency variable voltage, or customized according to customer needs.
The above four functions can be added according to user needs, and the cost will be charged separately!
Main technical requirements:
Input voltage:AC 220 V
Output voltage:AC 0--100 kV DC 0-100 kV
Boosting method: Continuous boost,20Gradually increase voltage and withstand voltage in seconds
Electrical capacity:6 KVA
High voltage classification:0--100kV(Full range without grading)
Breakdown voltage:0--100kV
Boosting rate: Can achieve stepless speed regulation and free setting of boost voltage（0.1-6.0 kV/s）
Voltage measurement accuracy （10%--100%FS）： ≤ 1％
Test voltage: ０-100 kVContinuously adjustable
Test method: Communication experiment DC test (Dual use)
Boosting method: DC test:1Constant speed boosting 2Gradient Boosting 3Voltage withstand test
Communication experiment:1Constant speed boosting 2Gradient Boosting 3Voltage withstand test
There are two ways of stopping:1Voltage judgment stop 2Current judgment stop
Test method: 1Insulation sample air test 2Insulation sample immersion test in oil
Test medium: 1air 2Test oil
Overcurrent protection device: During the breakdown of the sample0.1SCut off the power supply internally.
Leakage current selection:【0-100mA】Free to set(Determine optional based on the capacity of the test transformer)standard0-50mA.
Overcurrent protection device: in case of sample breakdown0.01SCut off the power supply internally.
runtime environment:The instrument is15 ～ 30℃The temperature and0～85%It can operate stably under relative humidity.
Experimental environment: temperature15Degree to25Between degrees, relative humidity60%Go to70%Between them.
power supply:The instrument is220V±10%Single phase AC voltage and50H±1%It can operate stably at a certain frequency, and the configuration includes various power lines, grounding wires, and signal cables required for the normal operation of the instrument
Software Description:
1. The device can dynamically draw test curves during the testing process, and the test curves can be overlaid with multiple colors for comparison
2. Can edit and modify experimental data, flexible and applicable
3. The experimental conditions and test results can be stored as data
4. Can manually select the validity of curve data in a set of experiments
5. The experimental result data can be importedEXECL
6. The software operation interface allows operators to operate freely and has a more user-friendly interface.
Setting instructions
Testing unit: The name of the unit that conducts testing and inspection on the material.
Test method: Choose to conduct“Communication experiment”or “DC test“When conducting a DC test, the short-circuit rod needs to be removed.
Test method: Can be conducted“puncture”，“pressure resistance”，“Gradient withstand voltage”Experiment.
Test personnel: Enter the name of the testing personnel.
Test temperature: Enter the test temperature.
Test humidity: Input the test humidity.
Electrode shape: Input electrode shape.
Electrode size: Input electrode size.
Peak voltage drop: used to determine whether a material has broken down, and a momentary drop in voltage exceeding this value is considered breakdown.
Stop current judgment: used to determine the low current during breakdown, exceeding this current is considered breakdown.
Initial voltage: used for withstand voltage and gradient withstand voltage tests, where the voltage is raised at the beginning of the test.
Step by step voltage: used for gradient withstand voltage test, setting the gradient value of the boost.
Step by step time: used for gradient withstand voltage test, set at the corresponding gradient withstand voltage time.
Material Name: Set the name of the test material.
Test time: Select the test date.
Sample shape: Set the sample shape.
After setting up“Parameter Settings”Afterwards, click“Start the experiment”Button, start the experiment.
After completing the experimental task, it will display“Should the experimental data be retained”If clicked“yes”Insert the experimental results into the data list. At this time, the test number will be automatically assigned+1The experiment can continue.
print report:After the experiment is completed, you can click on the toolbar“print report”Button, print report.
Safety instructions for the use of high-voltage equipment:
◆ 100kVThe above voltage test is conducted in a high-voltage shielding room, and the operator operates outside the shielding room.When the experimental operation door is opened,Equipment high voltage power input cut-off.There is no output voltage on the high voltage side.150KVThe close distance between the high-voltage electrode of the testing equipment and the shielding chamber wall is650mmEven if people come into contact with the box wall during the experiment, there will be no danger.
◆The equipment needs to be equipped with a separate protective grounding wire. Grounding protection is mainly used to reduce the strong electromagnetic interference caused by the breakdown of the sample to the surrounding area. It can also prevent the computer from losing control.
◆The circuit of the experimental equipment is equipped with multiple protection measures, mainly including overcurrent protection, voltage loss protection, leakage protection, short circuit protection, DC test discharge alarm, etc.
◆Level 6 high-voltage safety power-off control:
①main power switch
②High voltage power-off switch (key switch)
③Voltage regulator reset switch
④Test box door safety switch
⑤High voltage transformer input side current limiting circuit breaker
⑥Leakage protection switch
Attention: This instrument is a high-voltage testing equipment, and the following points must be noted when using it
There should be an independent grounding wire during instrument installation.
Before starting up, the operator should first familiarize themselves with the operating method.
The instrument cannot be used in gas environments with strong corrosive gases and particulate impurities.
Test environment temperature15Degree to25Between degrees, relative humidity60%Go to70%Between
It is normal for sparks to be generated and accompanied by sound at the moment of sample breakdown.
Every time the sample is replaced or the high-voltage electrode is in contact, the high-voltage electrode must be discharged with high voltage for a certain period of time5秒以上。
Preparation and processing of test samples: Prepare test samples from the selected samples. If a smooth surface electrode is to be used, the surface of the test sample in contact with the electrode should have as smooth parallel planes as possible without actual surface processing. The test sample should be small enough to prevent flashover during testing. For thin materials, using sufficient test samples will facilitate multiple tests on a single test sample. For thicker materials (usually with a thickness of2mmAbove), there should be sufficient insulation strength to prevent flashover or strong surface partial discharge (corona) before breakdown. The techniques used to prevent flashover or reduce partial discharge (corona) include immersing the test sample in insulating oil during testing. The influence of environmental media factors on breakdown can be found inX1.4.7For test samples that are not dry and immersed in oil, as well as those that follow theD2413For test samples prepared according to operating procedures, this is usually necessary. Process a groove or drill a flat bottomed hole on one or both sides of the test to reduce the thickness of the test. If different electrodes are used (as shown in the table)1in6If there is a type of electrode, only one surface needs to be machined, and the larger of the two electrodes should be connected to the machined surface. Be careful when processing test samples to avoid contamination or mechanical damage to the test samples. Wrap a seal or fairing around the electrode connected to the test sample to reduce the occurrence of flashover. Uneven materials should be tested using test samples (and electrodes) that are similar in shape to the sample material. It is necessary to determine the test samples and electrodes used for these materials according to the material specifications. Regardless of the shape of the material, if other tests are required besides testing the face-to-face breakdown strength, the test sample and electrode used should be specified in the material description. In almost all cases, the actual thickness of the test sample is important. Unless otherwise specified, the thickness of the area adjacent to the breakdown point should be measured after testing. Should be at room temperature（25±5℃）Conduct measurements and based onD374The testing method adopts an appropriate process.
ASTM D149-2009The dielectric breakdown voltage test method and the withstand voltage breakdown tester adjust the breakdown strength of most solid insulators, which is affected by temperature and humidity. Therefore, before testing, the materials affected by this should be balanced with controlled temperature and relative humidity. For this material, adjustments should be included in the standards referenced to this testing method. Unless otherwise specified. Otherwise, it should be pressedD618Follow up procedures for operating procedures. For many materials, the effect of humidity on breakdown strength is greater than the effect of temperature. Adjust the material for a sufficient amount of time to ensure that the test sample reaches both humidity and temperature equilibrium simultaneously. If condensation occurs on the surface of the test sample during adjustment, the surface of the test sample should be wiped dry before testing. Usually, this can reduce the possibility of surface flashover.
Process of voltage breakdown tester (note: please refer to section before starting any test)7Chapter. ）Method of using voltage: MethodARapid testing method—As shown in the figure1As shown, from zero to breakdown, a uniform voltage is applied to the test electrode at a certain boosting speed. Unless otherwise specified, rapid testing method will be used. When determining the boost speed, in order to include the acceleration rate in the new specified value, for a given test sample, it should be selected to10to20sThe rate of breakdown occurs internally. In certain situations, it is necessary to carry out1to2Pre testing is conducted to determine the growth rate. For most materials, the use of500V/sThe growth rate. If the file refers to the growth rate of this testing method, even if the breakdown time occasionally occurs10to20sBeyond the scope, it should also continue to be adopted. If this situation occurs, the number of failures should be recorded in the report.
If a series of tests are to be conducted to compare different materials, the same rate of increase should be used, and the average time should be kept as close as possible10to20sbetween. If the breakdown time cannot be maintained within this range, it should be stated in the report. methodBStep by step testing——Apply a suitable starting voltage to the test electrode and follow the diagram2As shown, gradually increase the voltage until breakdown occurs. You can choose the starting voltageVsIn rapid testing, this voltage should be close to the measured or expected breakdown voltage50%If the starting voltage is lower than the figure2The listed voltages are recommended to be based on the starting voltage10%As a gradually increasing voltage. Under the specified voltage peak, the starting voltage should be raised from zero as soon as possible. The same requirement also applies to the increase in voltage between adjacent steps. After completing the initial steps, the time required to raise the voltage to the adjacent steps should be included in the time of the adjacent steps. If breakdown occurs during the process of increasing the voltage in the next step, the test sample has a tolerable voltageVwsIt should be equal to the voltage of the completed step. If breakdown occurs before the end of any step duration, test the endurance voltage of the sampleVwsCalculate the voltage according to the completed steps. breakdown voltageVbdUsed for calculating insulation strength. By thickness and voltage toleranceVwsCalculate the insulation strength. Request to exceed120sDuring the time, in10Occurred during the step4Secondary breakdown. If multiple test samples in a group have a breakdown frequency less than3Secondly, or if the time cannot be reached120sIn this case, the starting pressure should be lowered and retested. If in12Before taking steps or720sIf no breakdown occurs afterwards, the starting voltage should be increased.
Record the starting voltage, the number of voltage increase steps, the breakdown voltage, and the duration of the breakdown voltage. If the failure occurs when the voltage has just increased to the starting voltage, the failure time is0Other time lengths related to voltage steps should be specified based on the purpose of the test. The usual duration of use is20sto300s（5Minutes). For research, it is necessary to conduct tests on a given material for a normal length of time in certain situations. methodCSlow testing——Apply the starting voltage to the test electrode as shown in the diagram3Increase the voltage at the indicated rate until breakdown occurs. Select the starting voltage in the specified slow test. The selected starting voltage should meet the requirements. Starting from the starting voltage specified in the documents related to this testing method, increase the voltage at a certain voltage growth rate. Usually, the selected growth rate should be similar to the average growth rate gradually tested. If a group has multiple test samples that are not available120sIf breakdown occurs internally, the starting voltage should be reduced or the growth rate should be reduced, or both should be reduced simultaneously. If there are multiple test samples in a group whose breakdown voltage is less than the starting voltage1.5If it is doubled, the starting voltage should be reduced. If it is at the starting voltage2.5Under double voltage (as well as in...)120sAfter the breakdown occurs, the starting voltage should be increased as the breakdown continues to occur.
Appropriate starting voltage,Vsrespectively0.25, 0.50, 1, 2, 5, 10, 20, 50and100kV.
Step by step voltage | |
|
if Vs(kV)Ayes |
increment （kV） |
|
less than5 Yu5less than10 Yu10less than25 Yu25less than50 Yu50less than100 Yu100 |
Vsof10% 0.50 1 2 5 10 |
AVs=0.5(Slow testing)Vbd）Unless it cannot meet the parameters specified by the system. | |
|
System defined parameters （t1-t0）=（t2-t1）=…=（60±5）s Alternating step time. （20±3）sAnd（300±10）s 120s≤tbd≤720s，60Every second, every step | |
image2 Step by step test voltage schematic diagram
Growth rate（V/s）±20% |
System defined parameters |
1 |
tbd>120s |
2 |
|
5 |
|
10 |
Vbd=>1.5Vs |
12.5 |
|
20 |
|
25 |
|
50 |
|
100 |
image3 Schematic diagram of slow test voltage
ASTM D149-2009Dielectric breakdown voltage test method - Standard for breakdown——Dielectric failure or breakdown involves increasing conductivity to limit the maintenance of an electric field. In testing, this phenomenon can be clearly judged by visual inspection of the thickness of the transverse test sample and the sound of fracture. Within the breakdown area, it can be observed that the test sample is broken down and decomposed. This type of breakdown is usually an irreversible process. Repeated use of voltage can sometimes cause breakdown at low voltages (sometimes below measurable values), accompanied by other damages in the breakdown area. This type of repeated use of voltage often brings positive evidence of breakdown, which can make the breakdown path clearer and more visible. In some cases, a rapid increase in leakage current can cause the voltage source to trip without leaving any visible damage on the test sample. This type of failure is usually related to slow testing under high temperature conditions, which can cause reversible results. If the test sample is cooled to its initial testing temperature before reapplying voltage, its insulation strength can be restored. For such failures to occur, the voltage source will disconnect under relatively low current conditions.
In certain situations, voltage source disconnection can be caused by flashover, partial discharge, reactive current in high capacitance test samples, or faults in circuit breakers. Such interruptions in testing will not cause breakdown (except for flashover testing), and testing with such interruptions cannot be considered satisfactory. If the current set by the circuit breaker is too high, or if there is a problem with the circuit breaker malfunction, it will cause excessive combustion of the test sample.vDielectric breakdown: When the applied electric field strength exceeds a certain critical value, a breakdown occurs in the material Or there may be a breakdown where charges pass smoothly through“tunnel”Causing material damage, the medium is The phenomenon of dielectric state changing to conductive state. Dielectric strength: The critical electric field strength that causes breakdown of a medium. Under the collision theory of electric breakdown of solid media and strong electric field, some electrons exist in the solid conduction band due to cold or hot emission, These electrons are accelerated and gain kinetic energy; The interaction between high-speed electrons and lattice vibrations transfers energy to the lattice; When in equilibrium at a certain temperature and field strength, solid media have stable conductivity; When electrons obtain energy from the electric field and transfer it to the lattice vibration energy, The kinetic energy of electrons is increasing; At a certain value, the interaction between electrons and lattice vibrations leads to ionization New electrons rapidly increase the number of electrons, leading to unstable conductivity, A breakdown occurred. Compliance markGB/T1408.1-2016；IEC60243-1：2013；GB/T1408.2-2016；IEC60243-2：2013；ASTM D149；GB/T1695-2005；
Form of breakdown:
1Electric breakdown
A small number of individuals who were originally in a state of thermal motion under the influence of a strong electric field“free electron”Along the direction of the anti electric field Directional exercise. Continuously impacting ions in the medium during its movement,Simultaneously converting a portion of its energy Give these ions,When the applied voltage is high enough,The speed of free electron directional motion exceeds a certain threshold The threshold can ionize ions in the medium to release secondary electrons,These electrons will absorb energy from the electric field And accelerate,Another third level electron was struck,A chain reaction will cause the formation of a large number of free electrons “snow collapse” ,Causing breakdown of the medium,This process only requires10-7-10-8sthe time,Therefore Electric breakdown is often completed in an instant.
2Thermal breakdown
Insulation materials experience various forms of losses when working under an electric field,Partial electricity Can be converted into thermal energy,Heating the medium,If the heat generated inside the device The heat emitted by the device,Then heat accumulates inside the device,Raise the temperature of the device,The result of heating up further increases losses,Make it hot Further increase in quantity,The result of this vicious cycle is that the device temperature keeps rising rise,When the temperature exceeds a certain limit, the medium may experience phenomena such as burning and melting Elephants lose their insulation ability,This is the thermal breakdown of the medium.
Chemical breakdown
Long term operation in high temperature, humidity, high voltage, or corrosive gas environments The insulation material below often undergoes chemical breakdown,Chemical breakdown and materials The electrolysis, corrosion, oxidation, reduction, and gas electricity in the pores inside the material There is a close relationship between waiting for a series of irreversible changes,And it needs to be related
When for a long time,The material is“aging” ,Gradually losing insulation performance,Causing breakdown and destruction.
The mechanism of chemical breakdown:
(1)Under direct current and low-frequency alternating voltage,Electrolysis process caused by ionic conductivity,Materials sent Electroreduction effect,Causing a sharp increase in the electrical conductivity loss of the material,Due to intense heating, it becomes thermalization Learn to break through;
(2)When there are closed pores in the material,The temperature of the device is affected by the heat released by the free release of gas Rapid increase,Variable valence metal oxides accelerate the reduction of metal ions from high valence to high valence at high temperatures ion,Even reduced to metal atoms,Increase the electronic conductivity of materials,The increase in conductivity, in turn Make the device generate strong heat,Resulting in final breakdown.
Factors affecting electrical strength:
(1)Does temperature have an impact on electrical breakdown;Has a significant impact on thermal breakdown,The increase in temperature leads to an increase in the leakage current of the material,Loss increase,Increased heat generation plus,Promoted the occurrence of thermal breakdown;The increase in environmental temperature makes it difficult for the heat inside the device to dissipate,Further increasing the tendency towards thermal breakdown. The increase in temperature accelerates the chemical reactions of materials,Promote material aging,Accelerated the process of chemical breakdown.
(2)frequency
Frequency has a significant impact on thermal breakdown,In general,If all other conditions remain unchanged,thenEWearing and frequencywThe square root of is inversely proportional,namely:Measurement and Application of Electrical Strength:Under specific conditions,standardGB/T1408.1-2016; IEC60243-1:2013; GB/T1408.2-2016; IEC60243-2:2013; ASTM D149; GB/T1695-2005;Fixed the frequency breakdown voltage of solid electrical materials,breakdown field strength,Experimental method for voltage endurance. Regarding the dimensions of the sample,The shape of the electrode,The pressurization method and other regulations have been made.
The essence of thermal breakdown is that a medium in an electric field is heated due to dielectric loss; When the applied voltage is high enough, the heat dissipation and heating transition from equilibrium to non equilibrium Equilibrium state; If the heat generation exceeds the heat dissipation, the heat will accumulate inside the medium, causing it to The temperature of the substance increases; The increase in temperature leads to further increase in conductivity and loss, and the temperature of the medium The degree will continue to increase until sexual destruction occurs. Number of tests conducted——For specific materials, unless otherwise specified, they should be tested5Secondary breakdown. Select the continuous boost setting method:50KVvoltage breakdown,Usage range“50”,thus100KVvoltage breakdown,Usage range“100”Protecting current“5”, electrode size“75×25”or“25×25”Peak voltage drop,Set the breakdown voltage according to the small value of the sample,If lower than5KV,Can be set1KVfollowing. Step by step boost setting method: Set the initial voltage as follows“5”Gradient voltage, such as“5”The gradient time can be set according to the requirements of the body, and other settings are the same as the continuous boost setting. Slow boost setting method: The setting is the same as the continuous boost setting, except for multiple initial voltages, such as“5”just5KVThere is no curve below, the voltage rises to5KVOnly then did the curve emerge.
Keywords of voltage breakdown tester: breakdown, breakdown voltage, calibration, breakdown standard, dielectric breakdown voltage, dielectric failure, dielectric strength, electrode, flashover, power frequency, process control testing, verification testing, quality control testing, rapid increase, research testing, sampling, slow speed, gradual, environmental medium, withstand voltage.
The significance of insulation strength testing briefly reviewed three assumed mechanisms of breakdown, namely:（1）Discharge or corona mechanism, （2）Thermal mechanism, and（3）Inherent mechanism, discussed the factors that affect actual dielectrics in principle, and provided assistance for data interpretation. The breakdown mechanism is often combined with other mechanisms rather than acting independently. The subsequent discussion will only focus on solid and semi-solid materials. The assumed mechanism of dielectric breakdown is caused by discharge induced breakdown——In many tests conducted on industrial materials, breakdown is caused by discharge, which typically results in high local fields. For solid materials, discharge often occurs in the environmental medium, so increasing the testing area will result in breakdown at the edge or outside of the electrode. The discharge will also occur in some foam or bubbles that appear or are generated inside. This can cause local erosion or chemical decomposition. These processes will continue until a failure pathway is formed between the electrodes. Thermal breakdown——When placed in a high-intensity electric field, heat accumulates on local paths within many materials, causing a loss of dielectric and ionic conductivity, which rapidly generates heat that can be dissipated. Due to the thermal instability of the material, breakdown occurred.
Inherent breakdown——If neither discharge nor thermal stability can cause breakdown, then breakdown will still occur when the electric field strength is strong enough to accelerate electrons through the material. The standard electric field strength is called intrinsic insulation strength. Although the mechanism itself may have been involved, this testing method still cannot test the inherent insulation strength. The properties of insulating materials: Solid state industrial insulating materials are usually non-uniform and contain many different dielectric defects. The areas where breakdown often occurs on the sample are not those with high electric field strength, sometimes even those far away from the electrode. The weak links in the stress roll can sometimes determine the test results. Factors affecting testing and test sample conditions——Usually, as the electrode area increases, the breakdown voltage decreases, and this effect is more pronounced for thin specimens. The geometric shape of the electrode can also affect the test results. The material used to make the electrode can also affect the test results, as the thermal conductivity and work function of the electrode material can affect the thermal and power generation mechanisms. Generally speaking, it is difficult to determine the influence of electrode materials due to the lack of relevant experimental data. sample thickness——The insulation strength of solid industrial insulation materials mainly depends on the thickness of the sample. Experience has shown that for solid and semi-solid materials, insulation strength is inversely proportional to the fraction with the sample thickness as the denominator. More evidence suggests that for relatively uniform solids, insulation strength is inversely proportional to the square root of the thickness. If the solid sample can be melted and poured between fixed electrodes and solidified, it will be difficult to define the effect of electrode spacing clearly. Because in this case, the electrode spacing can be fixed freely, it is customary to conduct insulation strength tests in liquids or soluble solids, where there is a standard fixed space between the electrodes. Because insulation strength depends on thickness, if the initial thickness of the test sample used for testing is missing when reporting insulation strength data, such data will be meaningless.
During the casing test, it should be installed horizontally or vertically. If it is required to be installed in other states, it should be agreed upon by the supply and demand parties.
The ambient temperature during the experiment and the temperature of the immersion medium should be within10℃~40℃between. The experimental procedure is as follows:
1)Boost to U3=1.1U√√3=699kV, Continuously5min;
2)Boost to U₂=1.5 U√3=953kV, Continuously5min;
3)Boost to U=Uy=1100kV, Continuously1min;
4)Reduce pressure to U₂sustain5min;
5)Reduce pressure to U₃sustain5min;
6)The voltage drops to zero.
At all test voltages, the amount of partial discharge should be monitored and the measurement results recorded. Partial discharge does not show a continuous increasing trend and occasionally occurs
The higher amplitude pulses may not be included.
There should be no flashover or breakdown during the test, and the casing should be retested after the testtanδIf there are no abnormalities in the capacitance, the next test can be conducted. in
At any stage of the test, the upper limit of partial discharge of the casing is shown in the table4.
The tap insulation test should be conducted in1kVand2kVMeasure the test tap under the test voltagetanδAnd capacitance. The insulation data and requirements for the tap of the casing are specified in this standard7.3.
Ok/e
The temperature rise test of the casing should comply withGB/T4109-2008Chinese8.7In accordance with this standard7.4The regulations. The installation method of the hot short-term current withstand test sleeve can be agreed upon by the supply and demand parties through mutual agreement,The current value through the conduit conductor should be at least equal to this standard7.5Before the standard value test, a current should be applied to the bushing to ensure that the bushing conductor reaches a stable temperature, which should be the same as the stable temperature achieved by the bushing when the rated current is applied at high ambient temperatures. When there is no insulation damage after the test, the casing can proceed to the next test. The cantilever load tolerance test is conducted to verify that the casing complies with this standard7.7According to the regulations, the casing should be in accordance withGB/T4109-2008Chinese8.9The prescribed test method is used for testing, and the load applied during the test is5kNOil immersed paper oil-SFSealing test of casing for oil immersed paper oil-SFThe casing needs to undergo sealing tests in both type tests and individual tests. During the type test, fill the transformer oil and place it in a temperature that can last continuously12hmaintain at75℃Inside an appropriate heating container. During the experiment, appropriate methods should be used to maintain a low pressure inside the casing that is higher than its high operating pressure0.1MPa±0.01MPaWhen conducting individual experiments, the ambient temperature should not be lower than10℃Charge at low temperature60℃After filling the transformer oil, it is necessary to apply a high operating pressure to the inside of the bushing as soon as possible0.1MPa+0.01MPaAt least maintain the pressure12hThe casing should have no leakage during or after the experiment. The testing method should comply withGB/T2423.23-2013The relevant regulations. The external pressure test casing should be assembled according to the requirements of the test, and its switchgear side should be installed in a box as close as possible to normal operation at ambient temperature, with the box sealed and filled with appropriate liquid. Apply inside the box3Multiple times the high operating gas pressure, with sustained pressure1minThe casing should not have mechanical damage(For example, deformation and rupture)When there are no signs of mechanical damage, the casing can proceed to the next test. Sealing test on flanges or other fastenersa)Sealing requirements for transformer side. The casing should be assembled according to the test requirements. At ambient temperature, the bushing transformer side should be installed on a box as in normal operation, and the box on the transformer side should be filled with relative pressure0.15MPa±0.01MPaMaintain the air or any suitable body15min, or filled with relative pressure0.1MPa±0.01MPaMaintaining oil pressure12hThe casing should have no leakage.b)Sealing requirements for switchgear side. The casing should be assembled according to the test requirements. At ambient temperature, the casing switch equipment should be installed on a box as in normal operation, and the box should be filled with high operating gas pressure according to normal operation requirementsSFGas or tracer gas. When required, the components on the side of the bushing transformer should be enclosed in a jacket. The inner cavity of the casing containing liquid should be emptied and a window should be opened to allow gas to freely flow into the outer casing. Equal to or equal to2hWithin the time interval, the gas concentration in the air inside the jacket should be measured twice
Introduction to experimental software:
The appearance of this device software is designed by professional graphic designers:
Personnel management: Multiple people can be added to use this software simultaneously Different personnel set different passwords Cross use without interfering with each other If one person uses it, the password can be deleted Directly enter the software)
Parameter management: optional high voltage protection Voltage endurance time is optional Gradient step optional , leakage current and overvoltage optional, sensitive leakage voltage optional, leakage optional The boost speed can be freely set（0-5kvThe test results for infinite loop insertion are optional Remote operation selection Selection of human-machine separation, etc
Result retrieval: Save and retrieve experimental results Personnel selection and transfer The test results can be organized and operated according to customer requirements , Support5Compare the color lines and automatically collect and add experimental data.
In modern industrial production and research fields, the insulation performance of materials is directly related to the safety and reliability of power equipment, electronic components, and various insulation products. The voltage breakdown tester, as the core equipment for evaluating the dielectric strength of materials, is widely used in industries such as power, electronics, aerospace, and new energy. This article will comprehensively analyze this key detection work from the aspects of working principle, technical characteristics, application scenarios, and selection points.
1、 Definition and function of voltage breakdown tester
Voltage breakdown tester（Dielectric Breakdown Tester）It is a specialized equipment that measures the critical voltage value of solid, liquid, or gas insulation materials when breakdown occurs under the action of a high voltage electric field. Its core function is to evaluate the dielectric strength of materials and the breakdown voltage they can withstand per unit thickness, providing data support for product quality control, material research and development, and safety standard certification.
2、 Working principle and technical characteristics
1. working principle
During the experiment, the instrument applies continuous or stepped AC voltage between the two poles of the sample/Direct current voltage until insulation failure (breakdown) occurs in the material due to excessive electric field. The device automatically records the voltage and current values at the moment of breakdown, and calculates the dielectric strength based on the thickness of the sample.
Key parameter: breakdown voltage（kV）Dielectric strength（kV/mm）Boosting rate（kV/s）.
Test mode: Supports short-term breakdown, withstand voltage testing (such as long-term constant voltage testing), etc.
2. Technical Features
High precision control: using digital voltage regulation technology, stable voltage output, and resolution up to0.1 kV.
Multiple safety protections: equipped with overcurrent, overvoltage, arc detection, and emergency power-off functions to ensure operational safety.
Intelligent operation: equipped with touch screen or computer software, supporting automated testing processes, data storage, and report generation.
Wide compatibility: compliant withIEC 60243TheASTM D149TheGB/T 1408Waiting for international and domestic standards.
3、 Core application areas
1. power industry
Evaluate the insulation layer of the cable (such asXLPETheEPR）The voltage resistance performance of transformer oil and insulation cardboard.
Detect the insulation reliability of high-voltage equipment such as lightning arresters and insulators.
2. electronics manufacturing
testPCBThe dielectric strength of substrates and packaging materials ensures the safety of components in high-voltage environments.
Verify the insulation dielectric properties of electronic components such as capacitors and inductors.
3. New material research and development
Compare and analyze the performance advantages and disadvantages of new insulation materials such as nanocomposites and polymer films.
Optimize material formula and process to enhance product high pressure resistance.
4. Quality Control and Certification
Provide industry standard compliant solutions for automotive wiring harnesses, new energy battery separators, and aerospace insulation components, such asULTheCE）The testing report.
Selection and usage precautions
1. Key selection points
Test material type: Solid, liquid, or gas, corresponding electrode structure and container should be selected.
Voltage range: Select the equipment range based on the material breakdown threshold (e.g0-50 kVOr higher).
Standard compliance: Ensure that the instrument meets the specific testing standards of the target industry (such as healthcare).
Additional features: Some models support high temperature/Low temperature environment simulation, partial discharge detection, etc.
2. Precautions for use
Safe operation: The test should be conducted inside a shielded box to avoid harm to personnel caused by high-voltage arcs.
Sample preparation: The material surface should be clean and smooth, and the thickness measurement error should be less than1%.
Environmental control: Humidity and temperature may affect test results, it is recommended to operate under standard laboratory conditions.
Regular calibration: Annual verification of equipment accuracy through third-party organizations to ensure data reliability.
5、 Future Development Trends
1. intelligent upgrade
AIThe introduction of algorithms can achieve breakdown point prediction, automatic analysis of abnormal data, and improve detection efficiency.
2. Environmental protection and energy-saving design
Using low-energy high-voltage generators to reduce energy waste during the testing process.
3. Multi-functional integration
Integrated testing of parameters such as dielectric constant and dielectric loss angle to meet the requirements of comprehensive performance evaluation.
Conclusion
The voltage breakdown tester is used for the research and quality control of insulation materials. With the rapid development of new material technology, the requirements for equipment accuracy, safety, and intelligence will continue to increase. Proper selection and standardized operation can not only help enterprises avoid product risks, but also provide scientific basis for breaking through material performance bottlenecks. In the future, this device will continue to drive innovation and progress in fields such as power electronics and new energy.
The dielectric strength tester and breakdown voltage tester have highly overlapping functions and applications, and in many cases, their names may be mixed. However, depending on the design and testing standards, there may be slight differences as follows:
Differences in terminology definitions
Dielectric strength tester（Dielectric Strength Tester）
Measure the breakdown voltage per unit thickness of the material (i.e. dielectric strength, unit)kV/mm）Emphasize the quantification of the insulation ability of materials.
Standard Example:ASTM D149TheIEC 60243-1.
Breakdown voltage tester（Breakdown Voltage Tester）
Directly measure the voltage value (in units) of a material when breakdown occurs under specific conditionskV）Pay more attention to the voltage value at the critical breakdown point.
Overlap in actual use
Instrument hardware: Both usually use the same high-voltage generator, electrode system, and safety protection design.
Testing principle: Both methods gradually increase the voltage until the sample breaks down, and the difference mainly lies in the data processing method (whether it is divided by the thickness).
Industry habits:
Multiple names in the power industry“Breakdown voltage tester”(such as transformer oil testing).
Multiple names in the field of material research and development“Dielectric strength tester”(such as plastic, rubber).
selection suggestion
If intrinsic properties of the material are required: choose a dielectric strength tester The result is independent of thickness and facilitates horizontal comparison.
If safety threshold verification is required: choose a breakdown voltage tester (directly obtain the actual withstand voltage).
Note: Some modern instruments can output two types of data simultaneously (such as those from Beiguang Jingyi Instrument Equipment Co., Ltd.)BDJCSeries), the mode needs to be switched through software settings.
Method for recording breakdown voltage of voltage breakdown tester
Record the process and key stepsInitialization settings
Set test mode through touch screen (continuous)/Step by step, boost rate（0.1-5 kV/s）And breakdown current threshold (default)5mA）Ensure that the parameters meet the requirements of material testing standards68.
Calibrate the electrode spacing (such as using a micrometer to adjust to millimeter level accuracy) to ensure even contact between the electrode and the sample.
Real time monitoring and triggering capture
After starting the test, the device real-time draws the voltage-Current curve, when the current suddenly increases to the set threshold or arc discharge is detected, the system automatically locks the peak voltage at the moment of breakdown.
Some instruments support manual triggering of recording mode, which prompts the operator to manually save data by observing sudden changes or abnormal sounds in the voltmeter.
Data storage and output
Breakdown voltage value（kV/mm）Automatically stored in device memory after timestamp association, supports exportCSV/PDFFormat report, some models can be connected to a thermal printer to directly output paper records.
The data sheet should include auxiliary information such as environmental parameters (temperature, humidity), boost rate, breakdown time, etc. to meet traceability requirements.
Core technology and equipment support
Closed loop control technology
Adopting high precisionADCModule (resolution up to)0.1kV）Real time sampling of voltage signals, combined withPIDAlgorithm dynamically adjusts the boost curve to avoid recording errors (accuracy) caused by step fluctuations≤±2%）.
Dual trigger mechanism
hardware triggerThrough overcurrent protection circuit (such as setting)10mACut off the high voltage directly (threshold) and record the current voltage value.Software triggeredBased on voltage-The analysis of sudden changes in the slope of the current curve is used to determine the breakdown point and is suitable for identifying weak breakdown signals.
Operating standards and error control
Calibration requirements
Regularly use standard voltage dividers to verify voltage indication errors（δ≤±1%）.
safety protection
After breakdown, it is necessary to use a discharge rod to contact the electrode and release residual charges. After the high voltage indicator light goes out and the voltage regulator returns to zero, the protective door can be opened to process the sample.
Attachment: Typical Data Record Representation Example
parameter |
numerical value |
unit |
Remarks |
breakdown voltage |
25.3 |
kV/mm |
ambient temperature23℃ |
pressure rate |
0.5 |
kV/s |
IEC 60243Standard Mode |
Breakdown current |
8.7 |
mA |
threshold setting5mA |
Through the above standardized process, the accuracy and repeatability of breakdown voltage recording can be ensured
Definition and analysis of termination current for voltage breakdown tester
1、 Basic Definition
Terminate current
The current threshold (usually in milliampere level) set during the testing process. When the tested material breaks down, the circuit current suddenly increases to this threshold, triggering the device to automatically stop boosting and record the breakdown voltage value. In the non breakdown state, the leakage current of the material is usually microampere level（1-10μA）At the moment of breakdown, the current will jump1-2An order of magnitude (such as≥1mA）Form a clear signal for determining breakdown.
2、 Function and Function
Core judgment criteria
By monitoring current transients to identify breakdown events, it is possible to avoid misjudgments that may arise solely from voltage fluctuations.
Security protection mechanism
After triggering the termination test, the equipment automatically cuts off the high-voltage output and starts the discharge program to prevent overcurrent damage to the sensor or the risk of arc.
3、 Parameter Setting Specification
Typical threshold range
The default value of the universal testing instrument is5mA, can be adjusted according to the conductive properties of the material1-20mA.
High sensitivity testing scenarios (such as thin film materials) can be reduced to0.5mATo improve detection accuracy.
Setting criteria
Material type: Materials with strong conductivity require a higher termination current threshold to avoid false triggering. Test standard: FollowIEC 60243TheGB/T 1408The body requirements for current threshold in the standard.
4、 Technical implementation
monitoring technology
Real time collection of current signals using high-precision microampere meters or Hall sensors, combined with digital filtering technology to eliminate environmental interference.
Linkage control logic
Current signal throughADAfter conversion, input the controller and verify it through hardware comparison circuit and software algorithm to ensure that the response time is less than50ms.
Attachment: Correlation between Termination Current and Other Parameters
parameter |
Association mechanism |
Typical example |
pressure rate |
High speed boost requires matching with higher termination current |
1kV/scorrespond to5mAthreshold1 |
Electrode morphology |
The electrode is prone to causing partial discharge, and the threshold needs to be lowered |
ball-Plate electrode setting3m |
ambient humidity |
Humidity>70%It is necessary to increase the threshold to prevent misjudgment |
Adjust the threshold to8m |
By setting the termination current parameter reasonably, the accuracy and safety of breakdown voltage testing can be significantly improved
Application fields and importance of voltage breakdown tester
1、 Application fields of voltage breakdown tester
power industry
Used for insulation performance testing of high-voltage transmission lines, transformers, and switchgear to ensure long-term stable operation of equipment in high voltage environments.
Applied to the safety assessment of substations and power grid equipment to prevent power system failures caused by insulation failure.
Electronic manufacturing industry
Test the insulation performance of electronic products such as circuit boards and semiconductor devices to prevent short circuits or safety accidents caused by insulation defects. Evaluate the voltage resistance of electronic components such as capacitors and cables to ensure the reliability and service life of the product.
New material research and development
Analyze the dielectric strength and withstand voltage limit of new insulation materials, and promote the development of high-performance materials such as nanocomposites and high-temperature superconducting materials. By simulating the environment through accelerated aging tests, the degradation law of insulation performance of materials under wet heat, mechanical stress and other conditions is studied.
Other industrial sectors
aerospaceVerify the electrical safety of aircraft cables and spacecraft insulation components.
Automotive ElectronicsTest the reliability of onboard batteries and motor insulation systems to adapt to the trend of high voltage in new energy vehicles.
communication equipment: Evaluation5GThe voltage resistance performance of base stations and fiber optic equipment ensures the stability of signal transmission.
2、 The importance of voltage breakdown tester
Core workers ensuring electrical safety
By accurately measuring the breakdown voltage, identifying the performance boundary of insulation materials, and avoiding accidents such as fires and explosions caused by overvoltage in equipment.
As a quality control measure in the manufacturing and maintenance of power equipment“Rear defense line”Reduce economic losses caused by insulation failure.
Promote technical standardization and compliance
The test data shows that the product complies withIEC 60243TheGB/T 1408Waiting for international/The key basis of domestic standards directly affects market access qualifications.
Provide quantitative support for the design optimization of electrical equipment, such as determining insulation layer thickness or material selection through breakdown voltage values.
Support scientific research and industrial upgrading
Assist in the research and development of new insulation materials, promote the miniaturization and efficient development of power equipment (such as ultra-high voltage transformers and compact switchgear).
Establish a material aging model based on long-term performance monitoring data to provide scientific basis for equipment life prediction and preventive maintenance.
Attachment: Typical Application Scenarios and Technical Requirements
field |
test subject |
Technical specifications requirements |
electrical equipment |
Transformer insulation cardboard |
breakdown voltage≥40kV/mm17 |
semiconductor |
Chip packaging epoxy resin |
leakage current≤1μA@10kV |
new energy vehicle |
Power battery separator |
compressive strength≥200V/μm |
aerospace |
High temperature resistant cable sheath |
Stability of breakdown voltage±2% |
The voltage breakdown tester has become a key infrastructure for ensuring electrical safety and driving industrial innovation through multi domain penetration and technological iteration
Operation process of voltage breakdown tester
1、 Equipment preparation and safety confirmation
Environmental and power inspection
Ensure that the laboratory temperature is controlled within15-30℃Humidity<70%To avoid environmental factors interfering with testing accuracy.
Connect the power cord（AC 220V±10%）Check that the grounding resistance is less than4ΩUse grounding rod depth>1.5Rice.
Power on and self-test
Press the power button to start the device and wait30Complete system self-test in seconds, confirm touch screen display“System Ready”Status.
Calibration voltage indication error（≤±1%）Verify the accuracy of the equipment using a standard voltage divider.
2、 Sample installation and parameter setting
Sample processing and installation
Cut the sample to standard size (e.g100×100mm）After surface cleaning, wipe with anhydrous ethanol to remove oil stains and dust.
Lay the sample flat on an insulated platform and adjust the distance between the upper and lower electrodes to the preset value (e.g1mm）Using a micrometer to calibrate accuracy up to±0.01mm.
Parameter Configuration
Select the test mode through the touch screen:Continuous boostStarting from zero, increase the voltage uniformly until breakdown;
Step up boostApply voltage in segments and maintain for a certain period of time.
Set the boost rate（0.1-5kV/s）Breakdown current threshold (default)5mA）And the initial voltage (recommended expected breakdown value)30%）.
3、 Test execution and data recording
Start testing
Close the protective door, press the start button, and the device will automatically increase the voltage, displaying the voltage in real-time-Current curve. When the current jumps to the set threshold (such as≥5mA）When arc discharge is detected, the equipment automatically stops boosting and records the breakdown voltage value.
exception handling
If overcurrent protection is triggered during testing (hardware)/Software dual protection), immediately cut off the high voltage and start the discharge program, and only operate after the residual charge is released.
4、 Data Management and Maintenance
output result
View historical data on the main interface and export itCSV/PDFFormat reports or output paper records through thermal printers.
The report should include traceability information such as environmental parameters (temperature and humidity), boost rate, breakdown time, and equipment serial number.
Equipment maintenance
Regularly clean the oxide layer on the electrode surface, sand it with sandpaper, and apply insulating grease.
Conduct monthly no-load tests to verify the stability of voltage rise and ensure its stabilityPIDControl algorithm accuracy≤±2%.
Safety precautions
protective measures
During the testing process, it is strictly prohibited to open the protective door. The sample should be processed only after the high voltage indicator light is turned off and the regulator is reset to zero.
Operators need to wear insulated gloves and goggles to avoid arc injuries.
Emergency handling
If the device gives an abnormal alarm (such as overcurrent or short circuit), immediately press the emergency stop button and disconnect the main power supply.
Through standardized operating procedures and multiple security protection mechanisms, the accuracy of test results and the safety of operators can be ensured
Sample processing procedure after voltage breakdown test
1、 Security protection and equipment reset
Power outage and discharge
Immediately turn off the high-voltage output after the experiment is completed, press the stop button or emergency stop button, and cut off the main power supply.
Waiting for the device to automatically discharge (approximately)30-60Confirm that the high voltage indicator light is off and the regulator is reset to zero before opening the protective door.
Residual charge release
Touch the surface of the sample with a grounding rod and manually release any residual charges to avoid the risk of electric shock for operators.
2、 Sample inspection and recording
Analysis of breakdown marks
Observe whether there are penetrating pores, carbonization paths, or cracks on the surface of the sample, and record the morphology of the breakdown point using a microscope or magnifying glass.
Measure the diameter of the breakdown point with an accuracy of0.1mm）Mark the distance between the breakdown location and the electrode contact area.
Abnormal status marker
If the sample does not break through but shows partial discharge traces (such as focal spots), it needs to be classified separately and labeled“Non breakdown”.
3、 Sample cleaning and storage
surface cleaning
Wipe the surface of the sample with anhydrous ethanol or acetone to remove any oxidation residues or carbides in the electrode contact area.
For samples that have been tested multiple times, they need to be cleaned and dried at a certain temperature≤60℃, Time≥2Hours) to restore the initial state.
Classified storage
The punctured samples are stored separately in anti-static bags and labeled with test parameters (such as breakdown voltage, ambient temperature and humidity).
Unpenetrated samples can be reused, but the cumulative number of tests must be recorded to avoid material fatigue affecting data accuracy.
4、 Data organization and equipment maintenance
Data export
Export breakdown voltage, current curve, and breakdown time data from the device and save them asCSVFormat and backup.
The report should include comparative photos of the sample before and after breakdown, as well as environmental parameters (temperature, humidity).
Electrode and equipment maintenance
Clean the surfaces of the upper and lower electrodes and use800Polish the oxide layer with sandpaper and apply silicone grease for rust prevention.
Check if there are any breakdown residues on the insulation platform, and if necessary, clean and dry it with isopropanol.
Safety precautions
Operating Specifications
It is strictly prohibited to come into contact with the sample before discharge or when the high voltage has not returned to zero. Insulated gloves and goggles should be worn for operation.
When dealing with porous or hygroscopic materials, it is necessary to extend the discharge time（≥5Minutes).
Through standardized sample processing procedures, the traceability of test data can be ensured and the service life of equipment can be extended
The process and principle of using a transformer paper breakdown strength tester to test the breakdown field strength are as follows:
1、 Testing principle
Formula for breakdown field strength
The breakdown field strength is calculated by the ratio of breakdown voltage to sample thickness, and the formula is:
E=UbdE=dUb
among which,UbUbFor breakdown voltage（kV），ddFor sample thickness（mm）.
Electric signal capture mechanism
During the experiment, the instrument gradually increases the voltage until the material breaks down. The current monitoring device captures the sudden change in current signal at the moment of breakdown and automatically calculates the field strength value based on the voltage data.
2、 Operation process
sample preparation
Prepare thin films or sheet-like samples with uniform thickness, measure and record the thickness (accurate to)±0.001mm）.
Select appropriate electrodes (such as diameter)25-75mmEnsure that the surface of the flat electrode is smooth and free of burrs.
Device Settings
Voltage modeSelect DC according to the material application scenario（DC）Or communicate（AC）Power supply.
pressure rateSet a constant rate (such as100V/sto5kV/s）Or stepwise boosting.
protection parametersConfigure overcurrent and overvoltage protection thresholds and emergency power-off functions.
Test Execution
Place the sample between the electrodes and gradually increase the voltage after applying the initial voltage.
Real time monitoring of voltage and current changes, automatic recording of breakdown voltage values at the moment of breakdown.
repeated test3-5Next, take the average to improve accuracy.
3、 Key influencing factors
Material PropertiesThe breakdown field strength of different dielectrics varies significantly, such as the different withstand voltage capabilities of plastics and ceramics.
Electrode designThe shape and edge treatment of the electrode affect the distribution of the electric field, and improper design can lead to partial discharge errors.
ambient temperatureAn increase in temperature may reduce the dielectric strength of the material.
pressure rateExcessive voltage rise may mask material defects, while too slow may prolong the testing cycle.
4、 Equipment core components
component |
Functional Description |
high voltage generator |
Provide stable high voltage output (such as0-50kVRange), supports continuous or step boosting. |
measurement system |
Integrate high-precision voltmeter and ammeter to collect real-time test data. |
control system |
Control the boost rate, testing time, and data storage, and some devices support custom programming testing processes. |
Safety protection device |
It includes multiple protection mechanisms such as overcurrent protection, discharge alarm, and emergency power-off. |
5、 Precautions
Standardization of electrodesPriority should be given to adopting international standards (such asIEC 60243）The specified electrode size and material.
multiple verificationsConduct multi-point testing on the same sample to avoid data deviation caused by local defects.
safety protectionShielding covers need to be installed in high-voltage testing areas, and operators need to wear insulated equipment.
How long does it take to test the breakdown field strength of transformer paper breakdown strength tester?
The breakdown field strength test time is mainly determined by the boost mode, material type, and environmental conditions. The body analysis is as follows:
1、 The impact of boost mode on testing time
Boosting method |
time range |
Applicable scenarios |
standard basis |
Rapid Boost |
10-20second |
Routine quality control testing |
IEC 60243series |
20Step by step boost in seconds |
Stay at each level20second |
High precision scientific research or complex material analysis |
Specification for slow breakdown test |
60Step by step boost in seconds |
Stay at each level60second |
Study the dynamic characteristics of material breakdown process |
Long cycle voltage withstand test |
Extremely slow boost |
300-600second |
Testing of ultra-thin materials (such as nanoscale films) |
Research on Precision Electrical Performance |
2、 Other key influencing factors
Material Properties
Low dielectric strength materials (such as plastic films) may only require seconds to minutes to complete testing;
High voltage resistant materials (such as ceramics) require multi-stage boosting to extend the testing time to several tens of minutes.
environmental conditions
High temperature testing (such as200℃）Preheating the sample in advance is required, which increases the total time consumption20-30minute;
Humidity control may cause fluctuations in testing time±15%.
Repetitive requirements
Standard tests usually need to be repeated3More than once, the total time is extended to a single test3-5Twice.
3、 Typical testing total time range
Test Type |
Single test time |
Total time consumption (including repeated testing) |
Conventional industrial quality inspection |
20second-5minute |
1-25minute |
Research grade precise testing |
5-30minute |
15-150minute |
high temperature/High voltage composite test |
30-60minute |
90-300minute |
Note: The above time does not include sample pretreatment and equipment calibration.
Manufacturing and Inspection Standards for Dielectric Strength Testing Machines
1TheGB1408.1-2006Test Method for Electrical Strength of Insulation Materials
2TheGB1408.2-2006Test Method for Electrical Strength of Insulation Materials 第2Part: Additional Requirements for Application of DC Voltage Test
3TheJJG 795-2004Verification Regulations for Voltage Endurance Testers
Standard Test Methods for Dielectric Strength Testing Machines
1TheGB/T1695-2005Determination method for power frequency breakdown voltage strength and withstand voltage of vulcanized rubber
2TheGB/T3333Test Method for Power Frequency Breakdown Voltage of Cable Paper
3TheGB12913-2008Capacitor paper
4TheASTM D149Test Method for Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulation Materials at Industrial Power Supply Frequency
Application scope of dielectric strength testing machine
Mainly suitable for testing the breakdown strength and withstand time of solid insulation materials such as wire sleeves, resins and adhesives, impregnated fiber products, mica and its products, plastics, film composite products, ceramics and glass under power frequency voltage or DC voltage; This instrument is computer-controlled and can quickly and accurately collect, process, access, display, and print various data during the experimental process. The experimental software is a powerful, easy-to-use, and visually intuitive experimental software system developed by our company. This instrument adopts computer control and human-machine dialogue to complete the power frequency voltage breakdown and power frequency withstand voltage test of insulation media.
The following is a standard operating procedure for voltage breakdown testers, suitable for dielectric strength testing of insulation materials, plastics, rubber, etc.:
Usage process of Beiguang Precision Instrument Voltage Breakdown Tester
1、 Preparation before testing
1. Safety confirmation
Ensure that the testing instrument is well grounded to avoid the risk of electrical leakage.
Check if the safety interlock device of the test cabin door is functioning properly (high voltage can only be activated when the door is closed).
Operators need to wear protective equipment such as insulated gloves and goggles.
2. Environmental Requirements
Laboratory temperature（23±2）℃Humidity（50±5）%(Reference)GB/T 1408.1 2016）.
No strong vibration or electromagnetic interference.
3. Sample preparation
According to standards (such asASTM D149TheIEC 60243）Cut the sample uniformly, without bubbles or impurities.
Clean the surface of the sample to avoid contamination that may affect the results.
4. Instrument inspection
Confirm power supply voltage（220V±10%）Stable.
Check the high-voltage electrode (spherical)/Whether the board is smooth and undamaged, and the spacing meets the standard (such as1mm~5mm）.
Inject insulating oil (during oil immersion test), and the liquid level should cover the sample.
2、 Test Settings
1. parameter input
After booting up, enter the control interface and set the following parameters:
test mode Fast boost, step boost or withstand voltage test.
Initial voltage Usually rated voltage50%(such as1kV）.
pressure rate (such as1kV/sThe2kV/sChoose according to the criteria.
termination condition : Breakdown current threshold (default)5~10mA）Or manually stop.
2. Sample installation
Place the sample between the electrodes to ensure a smooth and bubble free contact.
During oil immersion testing, the sample needs to be immersed and allowed to stand to eliminate bubbles（≥5min）.
3、 Test operation
1. Start testing
Close the test hatch and press“start”Key, the instrument automatically boosts the voltage.
Real time observation of voltage Current curve, when the sample breaks down, the instrument automatically shuts off and records the breakdown voltage（kV/mm）.
2. exception handling
If flashover occurs instead of breakdown (surface discharge), the sample needs to be cleaned and retested.
When the test is interrupted, press“Emergency stop”Cut off the high voltage with the key, discharge it before processing.
4、 Operation after testing
1. data recording
Record the breakdown voltage value, sample thickness, environmental parameters, and failure mode (location of breakdown point).
Calculate dielectric strength (breakdown voltage)/Thickness, unitkV/mm）， 取3~5The average value of the second test.
2. safety reset
Confirm that the voltage is reset to zero and the discharge is complete before opening the cabin door.
Clean the electrodes and oil tank, and turn off the power.
5、 Precautions
1. Safety Warning
It is strictly prohibited to operate with electricity or open the cabin door!
After breakdown, the sample may produce carbonization marks, and the electrode needs to be cleaned in a timely manner.
2. Maintenance requirements
Regularly replace the insulation oil (withstand voltage value)≥30kV/2.5mm）.
Calibration cycle:1Year (or500After the second test.
3. Standard reference
Typical dielectric strength of solid materials:
Polyethylene:20~50kV/mm
Epoxy resin:15~30kV/mm
The voltage breakdown tester can ensure the accuracy of test data and ensure the safety of personnel and equipment through standardized operation. The test results need to be comprehensively evaluated based on material standards and actual application scenarios.
Okay, this is a technical article about insulation withstand voltage testers, aimed at providing comprehensive and practical information.
Insulation withstand voltage tester: a key guardian of electrical safety
Introduction
Ensuring the safety and reliability of the insulation system is crucial in the design, production, and maintenance of electrical products. Insulation failure may lead to serious consequences such as electric shock, fire, and even equipment damage. Insulation withstand voltage tester (also known as high voltage tester, withstand voltage tester, etc.)It's shrimpThe tester is a key instrument specifically used to evaluate the insulation system's ability to withstand high voltage in electrical equipment. It detects potential insulation defects in advance by applying test voltages much higher than the normal operating voltage of the equipment, modeling or aging insulation conditions, ensuring personal and equipment safety, and ensuring that the product meets national and international safety standards.
1 Test purpose and significance
1. Detecting insulation defects: Discovering potential defects such as internal cracks, impurities, air gaps, weak points, assembly errors (such as insufficient creepage distance and electrical clearance), moisture, aging, etc. in insulation materials during production or use.
2. Verify insulation strength: Confirm that the insulation structure of the product does not experience breakdown or leakage current when subjected to the specified high voltage, proving that it has sufficient dielectric strength.
3. Meet safety regulations: It is a mandatory safety certification (such asIEC, UL, CSA, CCC, VDE, GBOne of the core testing projects. Almost all electrical and electronic products involving mains power or higher voltage must pass a withstand voltage test before leaving the factory.
4. Quality Control and Reliability Assessment: As an important quality control point on the production line, as well as an important means of product development, type testing, and post maintenance verification.
II Basic working principle
The core principle of insulation withstand voltage testing is to test the tested equipment（DUT）Apply a test voltage (DC or AC) much higher than its rated operating voltage to the insulation system and maintain it for a specified time, while monitoring the leakage current flowing through the insulation material.
Apply high pressure: The high-voltage generator inside the instrument generates precise and controllable high voltages (up to thousands or even tens of thousands of volts).
Current monitoring: A high-precision current detection circuit (usually connected in series in the high-voltage circuit or low-voltage return terminal) measures the current flowing through the tested insulator in real time. This current is very small when the insulation is good (usually in the microampere or milliampere range).
Judgment criteria:
Breakdown（Breakdown）： If there are serious insulation defects, breakdown will occur under high voltage, forming a low impedance path, and the leakage current will sharply increase (far exceeding the set threshold), and the instrument will determine it as a failure（FAIL）And immediately cut off the high-voltage output (protection)DUTAnd instruments).
Leakage current exceeds the limit: Even if no breakdown occurs, if the leakage current exceeds the preset upper limit alarm value, it is considered that the insulation performance does not meet the standard and judged as a failure（FAIL）.
By（PASS）： If the leakage current remains below the set upper limit value and no breakdown occurs under the specified testing time and voltage, it is judged as passing（PASS）.
III Main testing types（AC vs DC）
1. Communication voltage withstand test:
Principle: Apply sine wave AC high voltage (usually50Hor60HPower frequency).
Advantages:
More closely related to the voltage stress (AC) during actual operation of the equipment.
It can effectively detect defects caused by different dielectric constant layers (such as capacitance effect) inside insulation materials.
More friendly to capacitive loads such as long cables and motors, requiring less testing power (power)=Voltage current power factor, capacitive load current phase lead, low effective power.
Disadvantages:
The ability to locate insulation defects is relatively weak.
During the testing process, capacitive loads will absorb a significant amount of reactive current, requiring the instrument to have sufficient output capacity（VAValue).
After the test is completed, the capacitive load needs to be discharged.
Application: Widely used for factory inspection and safety certification testing of various low-voltage electrical appliances, household appliances, information equipment, small and medium-sized motor transformers, switchgear and other products.
2. DC withstand voltage test:
Principle: Apply a stable DC high voltage.
Advantages:
The testing current mainly refers to the actual leakage current (resistive current), which makes it easier to set precise current criteria.
More sensitive detection of insulation defects (especially concentrated defects) and clearer breakdown points.
The required testing power is small (power)=Voltage and direct current may result in lower instrument size and cost.
After the test is completed, the energy stored in the capacitive load is slowly released (attention should be paid to discharge safety).
Disadvantages:
Cannot simulate voltage stress under AC working conditions (such as polarity reversal and dielectric loss).
In multi-layer insulation or damp insulation, misleading results may occur due to charge accumulation.
Charging capacitive loads takes time, and the testing cycle may be slightly longer.
Application: Commonly used in high-voltage equipment (such as power cables, motors, generators, transformer windings), capacitive load equipment, and situations where precise measurement of small leakage currents is required. It is also commonly used for post repair testing to avoid further damage to damaged insulation caused by AC testing.
Selection principle: Prioritize following the safety standards and regulations corresponding to the product. When there are no clear regulations in the standard, it is necessary to determine the type of equipment being tested, the characteristics of the insulation structure, and the purpose of the test (factory inspection)vsDiagnosis) comprehensive selection. Many modern testers supportAC/DCTwo modes.
4 Core testing parameters
1. Test voltage: Core parameters. Values are determined by product standards (such asIEC 60335, IEC 60950, IEC 61010, GB 4706It is usually determined based on factors such as rated working voltage, insulation type (basic insulation, additional insulation, reinforced insulation), pollution level, etc. The common range ranges from several hundred volts to several thousand volts (for consumer electronics) and even tens of thousands of volts (for high-voltage equipment).
2. Testing time: The duration of applying high pressure. The standard is usually defined as1In seconds3In seconds60Wait a second. Commonly used shorter time on the production line（1-3Seconds) to improve efficiency; Type testing or diagnostic testing may take a long time（60Seconds or longer).
3. Leakage current upper limit: judgmentFAILThe key threshold. Standards usually specify a value (such as5mA, 10mA）Or calculation method. Accurate settings must be made based on standard requirements and the characteristics of the tested equipment. Setting too low may lead to misjudgment, while setting too high will lose meaning.
4. Slow rise time: The time required for the voltage to rise from zero to the set value. It can reduce the impact on the tested equipment and spark interference during testing. Standards may have requirements (such as5Seconds).
5. Slow descent time: The time for the voltage to drop to a safe value after the test is completed. Protect sensitive equipment and ensure operational safety.
5 Key components
1. High voltage generator: Core components that produce high precision and stabilityACorDCTest voltage.
2. Current detection unit: High precision measurement of flowDUTLeakage current.
3. controller: The microprocessor system is responsible for parameter setting, testing logic control, timing management, data acquisition and processing.
4. Comparison and judgment circuit: Real time comparison of measured current and set upper limit value, makingPASS/FAILJudging.
5. High voltage switch and protection: Quickly turn on and off high voltage output, and provide protection in case of breakdown or overcurrent.
6. interface: Display screen, keyboard/Knob, indicator light, alarm (sound)/Light is used for operation and result display.
7. Interface: RS232, USB, GPIB, Ethernet, Handler I/O (Pass/Fail, Start, Remote)Used for remote control, data recording, and integration into automated testing systems.
8. Safety interlock device: Ensure that the test cabin door is closed or the high voltage probe is connected before starting the test. During the test, the high voltage will be automatically cut off when the door is opened.
9. Grounding terminal: Ensure the safety of both the instrument itself and the operator.
VI Operating procedures and safety precautions (extremely important!)
Operation process:
1. preparation:
Carefully read the manuals of the instrument and the tested equipment.
Confirm testing standards and parameters (voltage, time, upper limit of currentAC/DC）.
Instruments andDUTReliable grounding.
Environmental inspection: dry, free of flammable and explosive materials, and without strong electromagnetic interference.
Wear necessary personal protective equipment (insulated gloves, insulated pads, etc., depending on the voltage level).
2. connect:
Turn off the power of the instrument.
Connect the high-voltage output line (usually red) toDUTThe tested conductor (such asL/NShort circuiting of terminals.
Return the instrument to the line/Connect the grounding wire (usually black) toDUTThe accessible metal components (grounding terminals or enclosures). (Note: This is a typical connection, and the body connection method depends on the testing requirements, such as testing ground insulation or insulation between different circuits)
Ensure that the connection is secure and not loose.
3. Set parameters: Set the test voltage, test time, upper limit of leakage current, and ramp up time on the instrument.
4. security check: Clear the site and confirm that no personnel have come into contact with the tested equipment and testing wires.
5. Start testing: Press the start button. The instrument boosts voltage, timing, and monitors current according to the set program.
6. Observation and judgment: The instrument automatically displays and records the test results（PASS/FAIL）Leakage current value. Pay attention to observe for any abnormalities (such as jumping fire, abnormal noise, burnt smell).
7. End and discharge: Test completed (regardless ofPASS/FAIL）After the voltage drops to zero, the instrument usually emits an end prompt sound. For DC testing or capacitive loads, be sure to use a discharge rod or wait for the instrument to fully discharge before disconnecting!
8. Disconnect and record: Disconnect the high-voltage line and return line, and record the test results.
Safety precautions (high voltage hazard!):
High pressure is deadly! During operation, high vigilance must be maintained and safety regulations must be strictly followed.
Reliable grounding: The instrument and the tested equipment must be well grounded.
Two person operation: High voltage (such as>1000V）It is strongly recommended to have two people operating the test, one person operating the instrument and one person monitoring.
Do not touch: During and immediately after the testing process (before sufficient discharge), it is strictly prohibited to touch any high-voltage parts (wires, terminals, tested points) and potentially live metal casings.
Safe Zone: Set up clear warning signs and quarantine areas.
Use interlocking: Ensure that the safety interlock function is functioning properly.
Insulation protection: Use qualified insulation workers (discharge rods, clamps), stand on insulation pads, and wear insulation gloves (depending on the voltage level).
Discharge confirmation: After testing, especiallyDCAfter testing, it is necessary to confirm that the high-voltage circuit has been discharged (using a discharge rod to contact and observe that the instrument voltage indication is zero).
Dry environment: Avoid testing in humid environments.
Device status: The tested equipment should be clean, dry, and have no external connections (unless required by testing).
Emergency stop: Familiar with the location and usage of emergency stop buttons.
7 Selection considerations
1. Output voltage range and type: Meet the requirements of the tested equipment standards（AC/DC）.
2. Output capacity (power): For communication testing, capacitive load is particularly important. Insufficient capacity may result in failed boost or inaccurate testing. Capacity is usuallyVA(Communication) orW(DC) represents.
3. Current measurement range and accuracy: It is necessary to accurately measure the small leakage current required by the standard and set an upper limit.
4. Compliance with safety standards: The design of the instrument itself must comply with relevant electrical safety standards (such asIEC 61010）.
5. Testing function: asAC/DCMode, slow rise/Slow descent, multi-step testing, contact inspection, arc detection, insulation resistance testing (integrated in some models), etc.
6. Human Computer Interface and Usability: Clear display and intuitive operation.
7. Data recording and interface: The ability to store test results and connect to computers or automation systems.
8. Security features: Reliability of interlocking devices, emergency stops, discharge indicators, etc.
9. Reliability and Brand Service: Choose a brand with good reputation and comprehensive after-sales service.
8 Frequently Asked Questions and Answers（FAQ）
QCan withstand voltage testing replace insulation resistance testing?
A: Cannot. The purpose and principle of the two tests are different. Insulation resistance testing (usually using a megohmmeter) uses lower DC voltage (such as500V, 1000V）Measure the resistance value (megaohm level) of an insulator to reflect the overall degree of moisture, dirt, or deterioration of the insulation. The withstand voltage test uses high voltage to test the instantaneous strength of insulation. The two are complementary and usually need to be carried out.
QWhy is the testing time usually1Second or60A second?
A：1Seconds are mainly used for rapid inspection of production lines, balancing efficiency and safety.60Seconds are used for more rigorous type testing or diagnosis, allowing potential defects to be exposed for a longer period of time.
QWhat is the appropriate leakage current setting?
AStrict adherence to the safety standards corresponding to the tested equipment is required! Different product categories, insulation types, and rated voltages have significant differences in their limit values. Common limits include0.5mA, 1mA, 3mA, 5mA, 10mAWait. Do not set it arbitrarily.
QWhat should I do if sparks appear during testing?
AThis is usually a sign of breakdown or severe flashover. The test should be stopped immediately (if the instrument does not automatically cut off), the power should be cut off and fully discharged, and the tested equipment and test clip should be carefully inspected to find the breakdown point or short circuit point. Repair before retesting.
QInstrument displayFAILBut does the tested device look fine?
APossible reason: The leakage current is set too low; Surface leakage caused by humid environment; Poor connection or contact resistance; There are slight defects inside the tested equipment (such as local moisture and dirt) that have not caused breakdown, but the current exceeds the standard; The instrument itself is malfunctioning. It needs to be gradually investigated.
9 Maintenance and Calibration
Regular calibration: The insulation withstand voltage tester is an instrument that requires strong testing or traceability of measurement values. Must be based on usage frequency and manufacturer/Metrological institutions recommend regular (usually annual) professional calibration to ensure the accuracy of their output voltage and current measurements meets the requirements. The calibration report needs to be properly stored.
Daily inspection: Before use, check the appearance (damaged wires, loose terminals), whether the grounding is good, and whether the safety interlock function is effective.
Keep clean and dry: Prevent dust and moisture from entering the interior of the instrument.
Proper storage: Store in a dry, non corrosive gas environment.
10 summary
The insulation withstand voltage tester is a testing equipment that ensures the safety performance of electrical products. It rigorously tests the dielectric strength of the insulation system by applying high voltage, effectively eliminating products with insulation defects, preventing safety accidents, and ensuring that products meet safety regulations in various regions. Correctly understand its working principle and testing type（AC/DC）The core parameters and strict adherence to safety operating procedures are key to the efficient, reliable, and safe use of this equipment. Whether in research and development, production, quality inspection, or maintenance, a reliable and standardized insulation withstand voltage tester is an important defense line to safeguard electrical safety.
References:
IEC 60335-1: Household and similar electrical appliances - Safety
IEC 60950-1: Information technology equipment - Safety (Already byIEC 62368-1substitute)
IEC 62368-1: Audio/video, information and communication technology equipment - Safety
IEC 61010-1: Safety requirements for electrical equipment for measurement, control, and laboratory use
GB 4706.1:Safety of household and similar electrical appliances 第1Part: General Requirements
Technical manuals and application guides from various instrument manufacturers
Please note: This article provides general technical information. Before conducting any actual testing operations, it is essential to carefully read and strictly comply with the operating manual of the instrument model you are using, as well as the specific safety standards applicable to the tested equipment. Safety is always there!
How does the dielectric strength tester determine breakdown
The dielectric strength tester (also known as the withstand voltage tester or high voltage tester) determines whether insulation materials have undergone electrical breakdown by monitoring the sudden changes in several key electrical parameters that occur during the application of high voltage. The following are the main criteria and methods for judgment:
1.current monitoring(core method):
principle:Before breakdown occurs, the current flowing through the insulation material is usually very small (mainly due to capacitor charging current and leakage current). Once breakdown occurs, insulation failure will form a low resistance channel at the breakdown point, causing a sudden and sharp increase in current (possibly several orders of magnitude).
judgment method:The instrument has set a current trip threshold. When the real-time monitored current value exceeds this preset threshold, the instrument determines that breakdown has occurred. This threshold is usually set at the milliampere level（mA）The body value depends on the testing standard, sample type, and testing voltage (e.g1mA,5mA,10mA,100mAEtc.).
key points:Choosing the appropriate current threshold is crucial. A low threshold may lead to misjudgment (identifying harmless leakage current or instantaneous interference as breakdown); A high threshold may lead to missed detection (small-scale breakdown not detected).
2.Voltage sag monitoring:
principle:When breakdown occurs, due to the formation of a low resistance channel, the voltage between the test electrodes will instantly drop (even close to zero).
judgment method:The instrument monitors the voltage applied to the sample in real-time. If the voltage drops sharply in a very short period of time (microsecond to millisecond level) to a level far below the set test voltage (such as a certain percentage below the set value, or below a certain value), it is judged as breakdown.
Attention:This method may not be very obvious when the internal resistance of the power supply is small or the impedance of the test circuit is low (because the power supply can quickly replenish current to maintain voltage), but it is more effective in series resistance or certain specific test circuits. It is often used as an auxiliary judgment for current tripping.
3.Arc detection(optics/acoustics):
principle:Breakdown is usually accompanied by strong arc discharge, producing visible light and/Or sound（“snap”The discharge sound.
judgment method:Some more advanced or application specific instruments may be equipped with photoelectric sensors (detecting arc flashes) or acoustic sensors (detecting discharge sounds). When these signals are detected, combined with changes in electrical parameters, breakdown can be more reliably determined.
application:Commonly used in laboratory research, situations with special observation requirements for breakdown processes, or as an auxiliary judgment when electrical parameter mutations are not significant. It is rarely used as the main criterion for judgment in standard production line testing.
4.circuit breaker tripping/The fuse is blown(Indirect and protective):
principle:The huge current generated by breakdown will cause the protective circuit breaker in the test circuit to trip or the fuse to melt, cutting off the high voltage output.
judgment method:The instrument detects an unexpected interruption of the high-voltage output (not manually stopped by the operator), usually accompanied by a sharp rise in current (before being cut off by the protective action), indicating that a breakdown has occurred.
Attention:This is usually seen as a result of a protective mechanism, rather than the primary means by which the instrument actively detects breakdown. The instrument itself will record whether current overload or voltage dip has been detected before the protective action.
Comprehensive judgment and safety measures:
Main criterion: For the vast majority of commercial dielectric strength testers, current exceeding the preset threshold is the core and main basis for determining breakdown.
Auxiliary criterion: Voltage sag monitoring is often used as an auxiliary criterion, combined with current criterion to improve the accuracy of judgment, especially when the current rise is not steep enough or the threshold is set close to the leakage current level.
Multiple safeguards: Instruments are usually designed with multiple protection circuits (overcurrent, overvoltage, short circuit protection) inside. Once breakdown or dangerous situations are detected (such as current exceeding the instrument's capacity), the high-voltage output will be immediately (usually within milliseconds or even microseconds) cut off to protect the safety of samples, instruments, and operators, and clear breakdown alarm signals (sound and light alarm, screen display) will be issued“puncture”or“FAIL”Etc.).
To prevent misjudgment: In order to avoid misjudgment caused by transient interference (such as switch noise), the instrument usually has a filtering circuit and appropriate delay judgment logic inside (to ensure that the current exceeds the standard continuously and significantly).
In summary:
The dielectric strength tester mainly monitors the test current flowing through the sample in real time and compares it with the preset current trip threshold. When the test current exceeds the threshold, the instrument immediately determines breakdown and cuts off the high voltage output. Voltage dip detection is a common auxiliary judgment method. Arc detection is used in specific demand scenarios. The action of protective devices (circuit breakers, fuses) is the response result of the protection system after breakdown occurs. The core of the instrument is to quickly and accurately capture the sudden change in current at the moment of breakdown and respond accordingly.
Power frequency withstand voltage testerThe definition is as follows:
Power frequency withstand voltage tester(also known asAC voltage withstand tester、Power frequency high voltage test deviceOr commonly known as“Apply pressure resistance”The device is a type ofElectrical testing equipment specifically designed to apply a power frequency AC test voltage far higher than its rated operating voltage to electrical equipment, electrical materials, insulation components, or insulation structures, and maintain this voltage for a specified period of time to assess their insulation withstand high voltage capability.
Core element analysis:
Power frequency:
The frequency of the test voltage generated by the equipment is the standard power frequency. In China and most European countries, it is50 HIn North America and other regions, it is 60 HThis is to simulate the AC voltage environment that the device is subjected to during actual operation.
Voltage resistance:
The core purpose of the experiment isTest the strength of the insulation system of the test sample.
Tolerance:Test whether the test sample can withstand high voltageNo breakdown occursorflashoverCan insulation be used“tolerance”Live under this high pressure without failure.Destructive testing:Voltage withstand test is usually considered asdestructive testingorstrength testIf there are serious defects in the insulation (such as cracks, impurities, aging, moisture, assembly errors, etc.), it may be broken down and discovered under high voltage during testing; On the other hand, the high voltage applied during the test itself may also cause cumulative damage to the originally qualified insulation.
Testing equipment/Device:
Voltage regulator:Used for smooth adjustment of input voltage (usually0~220Vor0~380V AC）.
Power frequency high voltage test transformer:The core component is to raise the low voltage output by the voltage regulator to the required high test voltage (such as several thousand volts to several hundred kilovolts).
Measurement system:High precision high-voltage divider (used to measure the actual high voltage applied to the test object) and measuring instrument (voltmeter).
Protector:Overcurrent relays, ball gap protection devices, current limiting resistors, etc. are used to quickly cut off high voltage in the event of breakdown of the test object or abnormal testing circuits, protecting equipment and operators.
Control system:Used for starting and stopping tests, setting test voltage and time, and integrating protection logic. Modern equipment typically includes microcomputer control units.
Alarm and indication:Breakdown alarm (sound and light), timer end indication, etc.
This is asystemIt usually includes the following key components:
Main functions and purposes:
Insulation strength verification:Verify whether the insulation of new products or newly installed equipment meets design requirements and safety standards (such asGB, IEC, IEEEEtc.).
Factory inspection:As a mandatory inspection item before leaving the factory for electrical products such as transformers, motors, cables, switchgear, insulators, household appliances, etc.
Preventive testing:Regularly inspect running equipment to identify insulation aging and potential defects.
Material evaluation:Evaluate the basic dielectric strength performance of insulation materials (solid, liquid, gas).
Fault diagnosis:Used to assist in diagnosing insulation faults (although breakdown points are usually more obvious).
安全性保障：Ensure that the insulation of the equipment has sufficient margin to prevent breakdown and ensure personal and equipment safety when encountering operating overvoltage or gas overvoltage during operation.
Differences from traditional high-voltage testers:
Function focus:It focuses onTolerance testOutput high voltage for a long time (usually60Maintain stability in seconds or according to standard regulations. Unlike partial discharge testers or dielectric loss testers, which focus on measuring subtle parameters inside insulation.
Output voltage waveform:Request to output standard sine wave power frequency high voltage.
Capacity:Sufficient power capacity is required（kVALevel) to drive potential capacitive loads (such as long cables, transformers) without causing significant voltage drops or waveform distortions.
Summary definition:
The power frequency withstand voltage tester is a device that uses a power frequency high-voltage test transformer to generate standard frequencies（50/60H）A professional electrical safety testing equipment that applies a high-voltage sine wave to the test object according to the prescribed test voltage and time to forcibly test whether its insulation system has sufficient strength to withstand short-term overvoltage without breakdown or flashover.It is a key testing method to ensure the insulation quality and operational safety of electrical products.
About“Nano material power frequency withstand voltage tester”：Essentially, it is still the power frequency withstand voltage tester defined above. Its uniqueness lies in:
Application scenarios:Specially designed for testing purposesnanomaterialsOr its composite insulation structure.
Possible accuracy/Control requirements:Due to the fact that nanomaterials may be more sensitive to voltage changes or require more precise research on their breakdown characteristics, such instruments may have higher requirements in terms of voltage control accuracy, waveform distortion, data sampling rate, or protection sensitivity.
Security considerations:The test volume may be small, requiring special design of electrodes and shielding measures.
Assistive function integration:Sometimes more precise data recording may be integrated or used in conjunction with other material performance testers.
The core function is still to apply standard power frequency high voltage and test insulation withstand capability.
Nano material power frequency withstand voltage tester Working principle and operation
Working principle
High pressure generation and regulation
adoptdry-type transformerorSeries resonance technology, generate0~10kVAdjustable power frequency AC voltage (frequency)30-300H）Apply a local high-voltage electric field to nanomaterials through micrometer level electrodes to simulate insulation conditions.
Key innovation: Micro electrode array achieves nanoscale loading, avoiding scale conflicts of traditional centimeter level electrodes.
Insulation performance monitoring
passUltra high sensitivity current sensor（≤1nA）Real time monitoring of leakage current, combined with voltage-Current phase difference analysis of dielectric properties of nanomaterials. At the moment of breakdown, the overcurrent protection is automatically triggered and the breakdown voltage value is recorded.
Microstructure coupling
integrationNano positioning platform(Precision)≤2nm）WithIn situ microscopy systemSimultaneously observe micro phenomena such as material deformation and breakdown paths under high voltage.
Operation process
step |
Key Operating Points |
security control |
1.sample preparation |
Nano materials are deposited on insulating substrates, with electrode spacing at the micrometer level (customized photolithography process required) |
Anti static operation table |
2.System Calibration |
Zero regulator, set voltage slope（1-2kV/s）Threshold current (such as10nA） |
Double grounding verification |
3.Boost test |
Uniformly increase the pressure to the target value (such as5kV）, voltage stabilization1minute; If the leakage current exceeds the standard or the material breaks down, it will automatically terminate |
overvoltage/Overcurrent dual protection |
4.data recording |
Save breakdown voltage and leakage current curves, and analyze failure sites in combination with microscopic images4 |
Thermal printing or digital export |
5.reset |
Reset the regulator to zero→Power off→Disassemble the sample after discharge |
Residual charge release detection |
Technological challenges and innovation directions
Scale adaptationNeed to break through microelectrode processing and nanoscale insulation shielding technology to prevent interference from surface discharge.
Signal noiseUsing electromagnetic shielding chamber and digital filtering technology, the interference of power frequency electromagnetic field on weak current signals.
Lack of standardsExisting standards (such asDL/T 848.2-20041）Only applicable to the establishment of a new evaluation system at the nanoscale.
noteThis type of equipment requires customized development, and can refer to the power frequency withstand voltage infrastructure and nanoindentation instrument positioning technology for joint research and development between industry, academia, and research.
The following is forPIMembrane (polyimide film) voltage breakdown testerCore technology analysis and operational standards:
Instrument functions and configuration
core functionality
determinationPIThe membrane ispower frequency AC/DC voltageThe breakdown strength below（kV/mm）And the withstand voltage time, in accordance withGB/T 1408-2006TheASTM D149Waiting for standards.
supportConstant speed boosting（0.1~0.5 kV/sAdjustable)Step by Step BoostingandWithstand Voltage TestThree modes, adapted to different testing scenarios.
Real time drawing of voltage-Current curve, record breakdown point data and export toEXCEL.
System Composition
high voltage generator: Output0~50kVAdjustable voltage（AC/DC）, Capacity≥2kVA.
Electrode systemStandard cylindrical electrode（Φ25mm/Φ75mm）Or customize micro spaced electrodes to meet thin film testing requirements.
safety protectionOvercurrent protection, leakage protection, interlocking power-off and discharge alarm devices for test box doors.
Key points for PI film specific testing
sample preparation
Cut flat samples (without wrinkles) with thickness deviation≤±1μmSurface roughnessRa≤0.2μmAvoid edge burrs.
Customization of micrometer level electrode spacing (photolithography process) is required to adapt to the characteristics of the film and prevent surface flashover.
Key parameter settings
parameter |
PITypical membrane requirements |
pressure rate |
0.2~0.5 kV/s |
breakdown threshold |
≥100 kV/mm(High performance)PI） |
Leakage current monitoring |
sensitivity≤1nA |
environmental conditions |
temperature23±2℃, humidity≤80% |
Operating procedures and safety standards
A[Power-on preparation] --> B{{ground check}}
B --> C[Place the sample]
C --> D[Set parameters]
D --> E{{Constant speed boosting}}
E --> F{Breakdown?}
F --yes --> G[record data]
F --No --> H[Voltage stabilization timing]
H --> G
G --> I[Discharge reset]
operation steps
Grounding verificationUse a multimeter to confirm that all ground wires are conductive, and lay insulation pads on the control panel.
Parameter SettingsSelect the boost mode and set the termination voltage (refer to)PIMembrane pressure resistance value150~300kV/mm）.
Boost testStart after closing the safety door, automatically draw a curve and mark the breakdown point.
data savingExport breakdown voltage, thickness conversion breakdown strength, and leakage current curves.
Safety Warning
Two person operationOne person tests, one person supervises, wears insulated shoes and hangs high-voltage warning signs.
Forced dischargeAfter cutting off the power, a discharge rod must be used to contact the electrode and release residual charges.
Emergency responseIn case of equipment failure, immediately press the emergency stop button or disconnect the main power supply.
Here isPIParameter setting and standardized operation process for sample installation of polyimide film voltage breakdown tester, comprehensive industrial specifications and safety requirements are summarized as follows:
1、 Parameter setting steps
Basic parameter configuration
voltage typeSelect AC or DC mode according to testing standards（PIThe membrane is recommended to undergo DC testing to reduce the impact of dielectric loss.
Test TypeSet to breakdown test mode (if voltage withstand test is required, select voltage withstand mode).
pressure rateSuggestion for uniform voltage increase 0.2~0.5 kV/s(High performance)PIThe membrane needs to be slowly pressurized.
cut-off voltage: PressPIMembrane pressure resistance value setting (usually≥150kV/mm, thickness0.1mmTime setting15kV）.
Security threshold setting
Current upper limitThe film material is set as 1~5nA(Prevent accidental triggering of micro discharge).
voltage upper limitNot exceeding the device value (such as50kVInstrument equipment≤45kV）.
Arc sensitivityEnable high sensitivity mode (detecting partial discharge).
Environment and sample parameters
inputsample thickness(Precision)±1μm）.
recordtemperature and humidity(Standard conditions:23±2℃, humidity≤80%）
Example operating interface: Open the software→Experimental setup→Select DC breakdown→Input boost rate0.3kV/s →Set upper limit of current3nA→Save parameters
Electrode processing
Wipe the ball with anhydrous ethanol-Ball electrode (standard configuration)Φ25mm）Ensure that there are no residual carbides.
toPIRecommended use of membraneCustomized micro spaced electrodes(Photolithography process, spacing)≤100μm）.
Sample preparation and placement
Cutting size≥100 ×100mm The edges of the sample should be polished smooth to avoid electric field distortion caused by burrs.
After eliminating surface static electricity, the ion fan is laid flat in the center of the electrode,Eliminate wrinkles or bubbles.
During the oil bath test, the transformer oil needs to immerse the sampleThe liquid level is higher than the upper electrode5mm）.
Safe locking
High voltage line connection: red (high voltage end) and black (low voltage end) correspond to the electrode interface.
Close the test hatch,Trigger access control switch linkage power-off protection
The following is about Voltage breakdown tester The standard usage process instructions are applicable to dielectric strength testing of insulation materials, plastics, rubber, etc.:
Usage process of Beiguang Precision Instrument Voltage Breakdown Tester
1、 Preparation before testing
1. Safety confirmation
Ensure that the testing instrument is well grounded to avoid the risk of electrical leakage.
Check if the safety interlock device of the test cabin door is functioning properly (high voltage can only be activated when the door is closed).
Operators need to wear protective equipment such as insulated gloves and goggles.
2. Environmental Requirements
Laboratory temperature（23±2）℃Humidity（50±5）%(Reference)GB/T 1408.1 2016）.
No strong vibration or electromagnetic interference.
3. Sample preparation
According to standards (such asASTM D149TheIEC 60243）Cut the sample uniformly, without bubbles or impurities.
Clean the surface of the sample to avoid contamination that may affect the results.
4. Instrument inspection
Confirm power supply voltage（220V±10%）Stable.
Check the high-voltage electrode (spherical)/Whether the board is damaged by light and the spacing meets the standard (such as1mm~5mm）.
Inject insulating oil (during oil immersion test), and the liquid level should cover the sample.
2、 Test Settings
1. parameter input
After booting up, enter the control interface and set the following parameters:
test mode Fast boost, step boost or withstand voltage test.
Initial voltage Usually rated voltage50%(such as1kV）.
pressure rate (such as1kV/sThe2kV/sChoose according to the criteria.
termination condition : Breakdown current threshold (default)5~10mA）Or manually stop.
2. Sample installation
Place the sample between the electrodes to ensure a smooth and bubble free contact.
During oil immersion testing, the sample needs to be immersed and allowed to stand to eliminate bubbles（≥5min）.
3、 Test operation
1. Start testing
Close the test hatch and press“start”Key, the instrument automatically boosts the voltage.
Real time observation of voltage Current curve, when the sample breaks down, the instrument automatically shuts off and records the breakdown voltage（kV/mm）.
2. exception handling
If flashover occurs instead of breakdown (surface discharge), the sample needs to be cleaned and retested.
When the test is interrupted, press“Emergency stop”Cut off the high voltage with the key, discharge it before processing.
4、 Operation after testing
1. data recording
Record the breakdown voltage value, sample thickness, environmental parameters, and failure mode (location of breakdown point).
Calculate dielectric strength (breakdown voltage)/Thickness, unitkV/mm）， 取3~5The average value of the second test.
2. safety reset
Confirm that the voltage is reset to zero and the discharge is complete before opening the cabin door.
Clean the electrodes and oil tank, and turn off the power.
5、 Precautions
1. Safety Warning
It is strictly prohibited to operate with electricity or open the cabin door!
After breakdown, the sample may produce carbonization marks, and the electrode needs to be cleaned in a timely manner.
2. Maintenance requirements
Regularly replace the insulation oil (withstand voltage value)≥30kV/2.5mm）.
Calibration cycle:1Year (or500After the second test.
3. Standard reference
Typical dielectric strength of solid materials:
Polyethylene:20~50kV/mm
Epoxy resin:15~30kV/mm
The voltage breakdown tester can ensure the accuracy of test data and ensure the safety of personnel and equipment through standardized operation. The test results need to be comprehensively evaluated based on material standards and actual application scenarios.
Selection guide for resin board withstand voltage tester
Introduction
Epoxy resin board, as an important insulation material, is widely used in power equipment, electronic appliancesPCBFields such as substrates. Its electrical strength or withstand voltage strength is a key indicator for measuring its insulation performance, which directly affects the safety and reliability of end products. The withstand voltage tester (also known as the breakdown strength tester) is the core equipment for conducting this test. Choosing appropriate instruments is crucial for ensuring the accuracy, reproducibility, and safety of test results and operators. This guide will systematically explain how to choose a suitable resin board withstand voltage tester from the aspects of core considerations, key parameters, brand recommendations, and selection process.
1、 Clearly define testing standards and core requirements
At the beginning of selection, it is necessary to clarify the following points, which are the basis for selecting all technical parameters:
1.Standards to follow: What international, national, or industry standards do you need to follow?
International standards: such asIEC602431,ASTMD149Wait.
National standards: such asGB/T1408.1(Equivalent adoption)IEC602431）.
Internal standards: Does your company or client have any special testing requirements?
The standard will clearly specify the testing methods (short-time method, stepwise boosting method), electrode size, boosting rate, sample size, etc., which directly determine the functional requirements of the instrument.
2.Test type:
AC voltage withstand test: Simulate the withstand voltage under power frequency conditions.
DC voltage resistance test: mainly used to test capacitive materials or evaluate insulation resistance, epoxy resin board testing may also involve.
Select backup communication according to standard requirements（AC）Direct current（DC）Or integrated AC/DC（AC/DC）The model of the function.
3.Sample type and size: Are finished boards or standard cut samples being tested? This is related to the electrode configuration (such as whether different sizes of column electrodes and plate electrodes need to be used) and the size of the testing chamber.
2、 Detailed explanation of core selection parameters
1.Voltage range and capacity
This is the core parameter.
Voltage range: The breakdown voltage of epoxy resin boards can usually reach several tenskVEven higher. You need to choose based on the expected breakdown voltage of the material and the testing voltage required by the standard.
Suggested scope: Select at least0~50kVThe model. For high-performance, thick specification epoxy boards, it is recommended to choose0~100kVOr higher range models to ensure sufficient margin.
Capacity (output current): determines the ability of the instrument to carry a load. During voltage withstand testing (non breakdown), if there are defects in the material (such as partial discharge), there will be leakage current. Instantaneous breakdown current is higher.
Suggestion: The AC test current should usually be≥100mA, DC≥10mAThe larger the capacity, the more stable the instrument, and the stronger its impact resistance.
2.precision requirements
Accuracy is directly related to the credibility of test data.
Voltage accuracy: usually should be better than±1%~±2%(Full scale).
Current measurement accuracy: usually should be better than±1%~±2%(Full scale).
Timing accuracy: For the step-by-step boosting method, the accuracy of the boosting rate and holding time is crucial.
3.Security protection function
The danger of high-voltage testing and safety are the primary considerations.
Door interlock switch: When the test cabin door is opened, it automatically cuts off the high voltage output.
Emergency stop button: One click power cut off in case of emergency.
High voltage warning light and sound prompt: Clearly indicate the high voltage status.
Reliable grounding system: The instrument must have good grounding.
Leakage current (breakdown current) protection: A threshold can be set, and when the leakage current exceeds this value, the high voltage will be automatically cut off and the sample will be judged as unqualified. This is the key function of voltage withstand testing.
Discharge function: After the test is completed, the residual charges in the sample and circuit will be safely discharged automatically.
4.Electrode system
Suitable electrodes need to be configured according to the standard.
Material: Usually brass or stainless steel, the surface should be smooth and flat.
Specifications: Common ones includeØ25mm/Ø75mmThe column plate electrodeØ6mmColumn electrodes, etc. Ensure that the instrument supplier can provide the electrode options required by your standards.
Installation method: Whether the operation is convenient, whether the adjustment is flexible, and whether it can ensure good contact between the electrode and the sample and uniform pressure.
5.Test medium (oil tank)
To prevent surface flashover (discharge on the surface of the sample rather than internal breakdown), testing is usually conducted in insulating oil.
Is it necessary to integrate an oil tank? Some desktop breakdown strength testers are integrated with transparent and safe organic glass or acrylic oil tanks.
Oil tank size: It should be able to accommodate your sample and electrode, and ensure sufficient insulation distance.
Type of oil: Special transformer oil or silicone oil should be used, and the supplier should be able to provide recommendations.
6.Control and Data Management Methods
Manual type: Adjust the boost through a knob, manually time and record data. Low price, but low efficiency, human error.
Fully automatic type (recommended): Controlled by a microprocessor, with built-in testing programs (such as short-time method, step-by-step boost method).
touch screen/LCD display: user-friendly human-computer interaction, intuitive parameter settings.
Automatic voltage boosting, timing, breakdown detection, and voltage reduction.
Data storage and output: capable of storing test data and passingUSBExport reports through the interface, or useRS232/Connect the network port to the upper computer software to achieve centralized data management and printing of test reports. This is standard equipment in modern laboratories.
3、 Brand and budget considerations
Domestic brand: Beijing Beiguang Jingyi Instrument Equipment Co., Ltd. In recent years, with rapid technological progress, stable product performance, rich functions, cost-effectiveness, and fast after-sales service response, it has become the mainstream choice in the domestic market.
Budget: Prices range from tens of thousands of yuan for domestic basic models to hundreds of thousands of yuan for imports. A balance needs to be struck between performance, functionality, brand, and budget.
4、 Summary of Selection Process
1.Requirement sorting: Clarify internal testing standards, sample specifications, daily testing volume, and budget range.
2.Market research: Collecting35Brand product catalog and technical solutions that meet the budget range of the home.
3.Parameter comparison: Create a comparison table, focusing on comparing the core parameters (voltage) mentioned above/Current range, accuracy, safety function, software function).
4.Consultation and Communication: Conduct in-depth communication with the supplier's technical sales team to confirm whether their equipment meets your standard requirements, and may request them to provide operational videos or demonstrations that comply with your standards.
5.After sales and service: Understand warranty policies, calibration services, repair response time, and spare parts supply situation.
6.Final decision: Make a choice based on three factors: comprehensive performance, price, and service.
Conclusion
Choosing a voltage resistance tester for epoxy resin boards is a highly technical investment. Never make decisions based solely on price. The core idea is to take testing standards as the outline, safety and reliability as the foundation, accuracy and functionality as the priority, and balance data management efficiency and long-term usage costs. It is recommended to prioritize domestic or imported equipment with fully automated control, improved security protection, excellent data management functions, and compliance with all your testing standards, in order to ensure that your research or quality control work is conducted efficiently, accurately, and safely.
I hope this guide can provide practical and effective assistance for your selection work.
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