- Industry background
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The battery pack industry is the core support for global energy transformation, driven by the rising penetration rate of new energy vehicles and the explosive demand for energy storage. The global market size of electric vehicle battery packs is expected to reach 85 billion US dollars by 2025, of which China's share has exceeded 45%. Technologically, lithium iron phosphate batteries are the mainstream, while emerging routes such as solid-state batteries (semi-solid batteries have gradually been installed) and sodium ion batteries (rapidly penetrating the energy storage field) are accelerating commercialization. Integrated technologies such as CTP and CTC continue to reduce costs and increase efficiency.
- Test requirements
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Safety requirements:
Battery packs (especially for electric vehicles and energy storage systems) belong to high-voltage electrical equipment (such as electric vehicle battery packs typically have a voltage of 300V~800V, and energy storage systems can reach over 1000V), which includes high-voltage positive and negative circuits inside, and low-voltage control units (such as BMS), metal casings, and areas accessible to the human body outside.
In response to the increasing demand for safety, the electrical safety standard system based on the electric vehicle industry chain stipulates that strict electrical performance inspections must be carried out in the production process to ensure that all performance indicators meet quality requirements.
Voltage withstand insulation test
The essence of withstand voltage testing is to simulate extreme insulation failure scenarios: by applying AC/DC high voltage far exceeding the normal working voltage (usually 1.5~2 times the working voltage, as required by standards such as GB 38031-2025, GB 44240-2024, etc.) between the "high voltage circuit and ground terminal (or shell)" of the battery pack for a specified time (such as 1 minute), monitoring whether the leakage current is within the safety threshold.
· If the insulation performance is qualified: the leakage current is extremely small (usually less than 10mA), it indicates that the insulation layer (such as the insulation skin of high-voltage cables, the separator of battery cells, and the insulation coating of the shell) can effectively isolate high voltage, preventing high-voltage electricity from "breaking through" the insulation layer and flowing into the shell or human body, thus eliminating personnel electric shock accidents from the root (such as touching the battery pack shell during maintenance or users accidentally touching faulty equipment).
· If the insulation fails: the leakage current exceeds the standard, it indicates that there is damage, gap or process defect in the insulation layer. High voltage electricity may directly conduct through the casing, causing electric shock casualties, or trigger a short circuit leading to more serious thermal runaway (fire, explosion).
test project
Test steps Test content test conditions Step One Positive electrode and shell Insulation impedance test
Output voltage 1KVDC, test time 5S, test result greater than 100M Ω Step two Negative electrode and shell
Insulation impedance test
Step three Positive electrode and shell
Voltage withstand test
Output voltage 1.6KVDC, test time 30S, test result less than 1mA Step 4 Negative electrode and shell
Withstand Voltage Test
- Solution
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Haoyi Technology is deeply involved in the field of electrical safety testing, and its HY9320-S8 series multi-channel AC/DC withstand voltage insulation tester perfectly solves the safety testing needs of multiple steps and points. It can achieve automation, informatization, and intelligence of safety testing, improve testing efficiency and time, and strictly and accurately test safety technical indicators.
Figure 1 HY9320-S8A AC/DC withstand voltage insulation tester
Figure 2 Test battery pack module assembly
Figure 3: Voltage withstand insulation test after wiring
The HY9320-S8A supports 8-channel dual end scanning testing, perfectly solving the limitations of single machine safety testing. In terms of program control programming, it supports storing 100 sets of test files internally, each file can be set with 20 different test programming steps, and supports multiple communication interfaces such as RS232/485, LAN, Handler, etc., helping enterprises reduce costs, achieve automated testing, improve testing accuracy and efficiency.
The technical indicators are as follows:
model HY9320-S4A HY9320-S8A Scan interface 4-way dual end 8-way dual end Contact inspection have have Withstand Voltage Test output voltage AC 0.050kV-5.000kV ± (1.0% set+5V) DC 0.050kV-6.000kV ± (1.0% set+5V) Current testing range AC 0.001mA-20.000mA ± (2.0% reading+5 words) DC 0.1uA-10.00mA ± (2.0% reading+5 words) Quick discharge function Automatic discharge after testing (DCW) Insulation resistance test output voltage 0.050kV-2.500kV (optional 5.00kV) Resistance testing range 0.1MΩ-100GQ Resistance testing accuracy ≥500V 1MQ-1GQ ± (5% reading+5 words)
1G Ω -10G Ω± (10% reading+5 words)
10MQ-50GQ ± (15% reading+5 words)
50GQ-100G Ω for reference only, no accuracy requirements
<500V
0.1MQ-1GQ ± (10% reading+5 words)
1GQ-100GQ is for reference only and has no accuracy requirements
Discharge function Automatic discharge after the test is completed ARC Detector measurement range AC Levels 1-9
Corresponding currents: 20mA, 18mA, 16mA, 14mA, 12mA, 10mA, 7.7mA, 5.5mA, 2.8mA
DC Levels 1-9 Parameter Settings Voltage rise time 0.1s-999.9s Test time setting 0.1s-999.9s (when TIMER ON) Voltage drop time 0s-999.9s, (Only after passing the withstand voltage) Voltage waiting time 0.3s-999.9s(Only DC withstand voltage, and it meets the requirement that the rise time + test time > waiting time) time accuracy ± (0.2% set value ± 0.1s) memory Programmable 100 test files, each file can have 20 test items memory Ordering Information Standard Accessories HY900R: A pair of high-voltage test clips
HY900B: High Voltage Test Rod
HY106: RS232 communication cable
HY917: Voltage withstand test line X2
HY913: Voltage withstand test line X4 (only HY9320-S4A)
HY913: Voltage withstand test line X8 (only HY9320-S8A)