During the process of wiring, including wire routing, insertion, organization, bundling, handling, and assembly of components, improper handling by personnel can result in damage to the insulation of the wire-wound components. This can lead to defects such as complete or partial short circuits between the same winding or between different windings. These faulty wiring components may experience corona discharge or spark discharge, weakening their insulation capability and reducing the reliability of the electric vehicle system. Over time, the accumulation of moisture and dust in pinholes or cracks of the wire insulation may cause motor or transformer failures. In severe cases, it can lead to burning and affect driving safety.
To enhance the electrical safety of electric vehicles (EVs), it is crucial to focus on the insulation performance of wiring components in the three electrical systems, such as motors, inductors, and transformers.
While component manufacturers typically use withstand voltage testers to check the voltage withstand capability and insulation capacity, they often overlook issues caused by inter-turn short circuits in enameled wires.
Withstand voltage testers apply high voltages at 50/60Hz but cannot detect inter-turn short circuit faults due to the resulting short-circuit condition in the tested device's coil.
During the process of wiring, including wire routing, insertion, organization, bundling, handling, and assembly of components, improper handling by personnel can result in damage to the insulation of the wire-wound components. This can lead to defects such as complete or partial short circuits between the same winding or between different windings. These faulty wiring components may experience corona discharge or spark discharge, weakening their insulation capability and reducing the reliability of the electric vehicle system. Over time, the accumulation of moisture and dust in pinholes or cracks of the wire insulation may cause motor or transformer failures. In severe cases, it can lead to burning and affect driving safety.
To enhance the electrical safety of electric vehicles (EVs), it is crucial to focus on the insulation performance of wiring components in the three electrical systems, such as motors, inductors, and transformers.
While component manufacturers typically use withstand voltage testers to check the voltage withstand capability and insulation capacity, they often overlook issues caused by inter-turn short circuits in enameled wires.
Withstand voltage testers apply high voltages at 50/60Hz but cannot detect inter-turn short circuit faults due to the resulting short-circuit condition in the tested device's coil.
MICROTEST 7750 Impulse Winding Tester utilizes non-destructive high-voltage, high-speed pulse measurement technology.
The 200MHz high-speed sampling captures dampened waveform, effectively detecting coil short circuit and insulation defects.
By applying a pulse voltage to the terminals of the winding coil, a damped oscillation waveform is generated through L/C resonance without damaging the test object. This allows for the comparison of instantaneous waveforms between a standard reference and the test object, enabling the early detection of faults such as interturn short circuits, internal coil defects, or insulation flaws in the magnetic core. This method ensures the quality and longevity of the product.
MICROTEST 7750 Surge Tester is designed for reliable insulation quality testing of high- and low-winding components. It utilizes non-destructive pulse voltage for waveform sampling and comparison, effectively detecting insulation issues in motors, transformers, BL inductors, and other components.
It supports pulse voltage outputs of 1200V, 5200V, and 10000V respectively, and employs 200MHz high-speed sampling technology to analyze subtle discharge faults. It offers six analysis and comparison modes, including total area comparison, area difference comparison, corona number comparison, jitter number comparison, second derivative comparison, and waveform comparison mode. With a testing speed of up to 10 times per second, it is the optimal choice for automatic production lines of winding components.
Molding Power inductor Test Solution｜7750-1
Molding power inductors are crucial in EV motor drive systems for energy storage and filtering circuits. They ensure stable power supply and minimize electromagnetic interference from high-frequency current pulses. However, during the manufacturing process of integrated molded inductors, issues like conductor or magnetic powder overflow and uneven electroplating can lead to interlayer short circuits. The 7750's second-order differentiation algorithm can effectively detect quality issues such as leakage caused by faulty solder joints in these inductors.
MICROTEST 7750 Surge Tester is designed for reliable insulation quality testing of high- and low-winding components. It utilizes non-destructive pulse voltage for waveform sampling and comparison, effectively detecting insulation issues in motors, transformers, BL inductors, and other components.
It supports pulse voltage outputs of 1200V, 5200V, and 10000V respectively, and employs 200MHz high-speed sampling technology to analyze subtle discharge faults. It offers six analysis and comparison modes, including total area comparison, area difference comparison, corona number comparison, jitter number comparison, second derivative comparison, and waveform comparison mode. With a testing speed of up to 10 times per second, it is the optimal choice for automatic production lines of winding components.
Molding Power inductor Test Solution｜7750-1
Molding power inductors are crucial in EV motor drive systems for energy storage and filtering circuits. They ensure stable power supply and minimize electromagnetic interference from high-frequency current pulses. However, during the manufacturing process of integrated molded inductors, issues like conductor or magnetic powder overflow and uneven electroplating can lead to interlayer short circuits. The 7750's second-order differentiation algorithm can effectively detect quality issues such as leakage caused by faulty solder joints in these inductors.
