New energy vehicles are on the rise, and at the same time, high-voltage insulation performance testing related to their safety is also receiving increasing attention.
What is High Voltage Insulation Test
High voltage insulation refers to the ability to isolate high voltage current under high voltage conditions. For the high voltage system of new energy vehicles, due to its generally high voltage, the guarantee of insulation reliability is very important. If there is a problem with the insulation performance of the high voltage system, it will lead to abnormalities in the entire new energy vehicle system, and even endanger personal safety. Therefore, conducting high-voltage insulation tests can not only verify whether the insulation performance of the vehicle's high-voltage system is qualified, but also ensure the passenger safety of both vehicle users.
What is high-voltage electrical component
Usually refers to high-voltage electrical components such as cables, battery packs, and circuit boards used in new energy vehicles. The insulation status of these high-voltage electrical devices is directly related to the safety and stability of automobiles.
The hazards of poor insulation
If the insulation status of high-voltage electrical components is poor, it can lead to serious consequences such as circuit short circuits, damage to electrical components, and even fire.
High voltage insulation testing methods
Common methods: direct measurement method, indirect measurement method
<Direct measurement method>
Directly apply a set voltage to the high-voltage device, detect its leakage current, and determine the excellent insulation status of the high-voltage device based on the magnitude of the leakage current.
Recommended testing device: HVT-1000 series HI-POT testing system (Shanghai Xinchong)
○ Equipment appearance

○ Reference standards
IPC-TM-650
System characteristics
1. Support AC/DC voltage output
2. Implement AC 5kV and DC 6kV voltage testing
3. Support 2kV insulation resistance testing
4. Three testing functions for voltage resistance, insulation, and voltage resistance+insulation are optional
5. Support multiple groups for simultaneous testing
6. The working conditions can be edited and reused for testing
7. Equipped with high-pressure fixtures and expanded testing channels
8. Chinese operation interface, automatic data saving, and automatic report generation
○ Technical parameters

<Indirect measurement method>
Add a set voltage to the high-voltage device, calculate the resistance value based on its leakage current, and indirectly determine the excellent insulation status of the high-voltage device based on the magnitude of the resistance value.
This method is a conventional method for high-voltage insulation testing of new energy vehicles. By testing the insulation resistance of the high-voltage system, it determines whether the insulation performance of the entire vehicle's high-voltage system meets the qualified standards.
When testing, it is necessary to first connect the test clamp to the tested high-voltage component, set the measurement voltage and other testing parameters, and then apply the set voltage with the ground disconnected. Based on the test results, determine whether the insulation resistance value of the high-voltage system meets the requirements.
Recommended testing device: SIR-9000 series (Shanghai Xinchong)
○ Equipment appearance

○ Technical parameters