Jianhu JH Series Dielectric Withstand Voltage Tester & Battery Dielectric Breakdown Strength Analyzer

Overview

The Jianhu JH Series Dielectric Withstand Voltage Tester and Battery Dielectric Breakdown Strength Analyzer is an industrial-grade high-voltage testing system engineered for precise evaluation of electrical insulation integrity in electrochemical cells, lithium-ion batteries, polymer electrolytes, solid-state battery components, and insulating materials. Operating on the principle of controlled AC/DC voltage ramping under standardized test conditions, the instrument measures the dielectric strength—the maximum electric field a material can withstand before catastrophic electrical breakdown occurs—expressed in kV/mm or V/mil. Designed to comply with core international test methodologies including IEC 62368-1, IEC 60243-1, UL 94, GB/T 1408.1, and IEEE Std 930, the JH Series supports both short-time (ramp-to-failure) and step-stress (incremental hold) test protocols, enabling rigorous assessment of insulation performance under simulated operational stress. Its architecture integrates galvanically isolated high-voltage generation, real-time leakage current monitoring (range: 0.1 µA–20 mA), arc detection circuitry with sub-millisecond response, and programmable dwell timing—ensuring reproducible, traceable, and auditable test outcomes essential for R&D validation, QC release, and regulatory submissions.

Key Features

• Programmable voltage output: AC 0–10 kV / DC 0–15 kV, adjustable in 10 V increments with ±1% full-scale accuracy per IEC 61000-4-8 calibration traceability
• Dual-mode operation: Continuous ramp-up (0.1–5.0 kV/s) and step-stress (predefined voltage levels with user-defined hold durations from 1 s to 600 s)
• Real-time safety interlock system: Dual-channel hardware-based emergency shutdown triggered by overcurrent (>20 mA), arc detection, door open, or ground fault
• Touchscreen HMI with intuitive workflow navigation: Parameter setup, test execution, pass/fail logic assignment, and immediate result display—all accessible without software installation
• Robust enclosure: IP2X-rated front panel, reinforced HV chamber with transparent polycarbonate shield (≥30 kV dielectric rating), and grounded copper mesh shielding for EMI suppression
• Compliance-ready data logging: Timestamped voltage, current, time-to-breakdown, and operator ID stored internally (≥10,000 test records) with USB export capability

Sample Compatibility & Compliance

The JH Series accommodates a broad range of specimen geometries and configurations, including coin cells (CR2032, CR2477), pouch cells (up to 200 mm × 150 mm), cylindrical cells (18650, 21700), prismatic modules (up to 300 mm × 200 mm × 50 mm), and flat insulating films (PET, PI, ceramic separators, gel electrolytes). Electrode contact is achieved via spring-loaded brass electrodes with adjustable pressure (0.5–5 N) and optional custom fixtures for edge or surface discharge testing. All test procedures align with GLP/GMP documentation requirements: audit trails record parameter changes, operator logins, firmware versions, and calibration status. The system supports optional 21 CFR Part 11-compliant software add-ons (sold separately) for electronic signatures, role-based access control, and automated report generation compliant with ISO/IEC 17025 laboratory accreditation criteria.

Software & Data Management

While the base unit operates standalone via embedded firmware, optional PC-based Jianhu TestSuite v3.2 software enables advanced data management. It provides waveform visualization (voltage vs. time, current vs. time), statistical analysis (Weibull distribution fitting for breakdown voltage clustering), batch reporting (PDF/Excel), and integration with LIMS via CSV or OPC UA. Calibration certificates include NIST-traceable references, and internal self-diagnostics verify HV transformer linearity, current sensor drift, and timer accuracy prior to each test sequence. Firmware updates are delivered via signed USB packages with SHA-256 verification to ensure integrity and prevent unauthorized modification.

Applications

This instrument serves critical functions across battery development and manufacturing: evaluating separator puncture resistance during nail penetration simulation; validating thermal-runaway mitigation layers; screening solid electrolyte grain boundary conductivity; verifying conformal coating dielectric performance on BMS PCBs; and certifying cell-to-cell insulation in multi-cell packs. Beyond battery systems, it is routinely deployed in quality assurance labs for capacitor dielectrics, motor winding insulation, medical device cable jackets (per IEC 60601-1), and aerospace-grade composite laminates. Universities and national metrology institutes utilize the JH Series for fundamental studies on space charge accumulation, partial discharge inception, and electromechanical degradation kinetics under combined thermal-electrical stress.

FAQ

What safety certifications does the JH Series carry?

The instrument complies with IEC 61010-1 (Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use) and carries CE marking with RoHS 3 compliance. High-voltage sections meet EN 61326-1 immunity standards.

Can the system perform tests per UL 1642 or UN 38.3 Section 38.3.1.3?

Yes—test profiles for cell-level dielectric withstand (e.g., 2× rated voltage + 1000 V for 1 minute) are preloaded and configurable within the HMI interface per UL 1642 Clause 10 and UN 38.3 Rev.7 requirements.

Is external grounding required for operation?

Yes—a dedicated low-impedance earth ground (<5 Ω) is mandatory per IEC 61000-6-3 and must be verified prior to first use using a calibrated earth resistance tester.

How often must calibration be performed?

Annual calibration is recommended; however, internal verification routines (per ISO/IEC 17025 §6.5) should be executed daily before test initiation using certified reference resistors and HV dividers.

Does Jianhu provide application support for custom test method development?

Yes—Jianhu’s Application Engineering team offers remote protocol development assistance, including ASTM D149/IEC 60243 adaptation, fixture design consultation, and failure mode correlation workshops for battery developers.