Dielectric testing is necessary to ensure electrical components have adequate insulation to protect users from electric shock. The most common test is the dielectric breakdown test, which monitors current leakage to determine if insulation has failed. The dielectric strength test is also conducted to detect defects during manufacturing.
Dielectric testing is an evaluation process performed by applying a voltage to an electrical component that exceeds its normal operating voltage. The purpose of the test is to determine whether the insulation of a component is adequate enough to protect the user from electric shock. This testing procedure is typically performed on electrical components, such as circuit boards, appliances, wires, transformers, and electric motors. The manufacturer of an electrical component typically tests it at the end of the manufacturing process, using a special device known as a dielectric tester.
Almost all electrical components lose some amount of electrical current due to a variety of different factors. This very small amount of current is considered safe for users, but under certain conditions, insulating materials or mechanisms can rupture and allow dangerous amounts to contact the user. This type of insulation failure can sometimes cause serious injury or death. Dielectric testing is necessary to ensure that the insulating mechanism of an electrical component withstands voltage changes under normal operating conditions.
The most common type of test is the dielectric breakdown test. In this procedure, a high voltage electric current is applied to the component. The dielectric tester monitors the amount of current leakage during the test to determine if the insulation has failed. High voltage current continues to be applied to the device until the insulation fails or the procedure time limit is reached. If the isolation mechanism fails, the product is generally considered safe for use. Electrical components that fail during dielectric testing are usually redesigned to meet safety requirements.
In addition to the dielectric breakdown test, a procedure known as the dielectric strength test is also conducted to determine if any defects have occurred during the manufacturing process. Electrical components sometimes contain small defects, such as gaps or spaces that can create an electrical short during normal operation of a device. Dirt, moisture, environmental contamination and vibrations can combine to produce a risk of electric shock if these manufacturing defects are not discovered prior to use by the consumer. In this procedure, electrical current is supplied to the component at its normal operating voltage. A dielectric tester is connected to the component to monitor the amount of leakage current present. If the leak levels are within an acceptable range, the component is approved for use.
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