Why Breakdown Voltage Matters
The reliability of the insulation system is vital in designing electric motors and high-voltage parts. Increasing performance demands, more power, higher energy density, smaller dimensions, push insulating materials closer and closer to their physical limits.
The breakdown voltage indicates the maximum limit beyond which insulation fails, leading to electrical discharges and permanent damage. Knowing this value is essential to validate materials, prevent defects, and ensure long-term component reliability.
From the Lab to Production: What’s Measured
In a laboratory environment, researchers gradually raise the voltage applied to the test sample to evaluate breakdown voltage. This may include components like a stator, hairpin, enameled wire, high-voltage connector, or cable harness.
During testing, several key parameters are monitored, including:
- Breakdown voltage (the exact point where the insulation fails)
- Leakage current
- Test duration
- Environmental conditions (temperature, humidity, pressure)
This information helps qualify materials and processes. It also gives important insights during prototyping and design optimization. Detecting potential weaknesses early means reducing production risks and improving the safety and quality of the final product.
EDC’s Answer: The Breakdown Voltage (BDV) Test System
To help researchers and engineers with this challenge, EDC created the BDV Test System. This is a high-voltage testing tool made for checking insulation.
The test bench can apply voltages up to 30 kV AC. It also has the option for DC testing up to 6 kV. This setup recreates extreme conditions in a safe and controlled environment.
The system stands out for:
- Versatility – tests on complete stators, hairpins, enameled wires, cable harnesses, HV connectors, and other insulated components.
- Precision – programmable voltage ramp, automatic breakdown detection, and test reports in CSV or PDF format.
- Safety – automatic discharge at the end of each test, mechanical interlocks, environmental sensors, and fume extraction systems.
- Integration – connection to MES or SCADA systems with complete test traceability.
The BDV Test System has an easy-to-use interface and customizable test recipes. Great for research, development, and industrial validation. This system ensures results are accurate and repeatable.
Understanding the limits of electrical insulation is essential for engineers designing machines and components for e-mobility and high-voltage applications. Using a special tool like the EDC BDV Test System gives you an edge. It reduces risks, speeds up development, and creates safer, more reliable products.
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