Insulation Coordination for E Mobility: New Challenges
Risk assessment for high voltage power electronics across three key factors: Technical Cleanliness, Ionic Contamination, and Coating.
Insulation coordination Special Challenges Require Innovative Solutions
In e-mobility, the requirements for insulation coordination are increasing significantly. We evaluate in a practical and data-based manner how Technical Cleanliness, ionic contamination and coating together influence high-voltage reliability. The result is a clear risk classification and an action plan, documented in a report suitable for internal decision making and OEM communication.
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Confidential and structured. With NDA on request.
insulation coordinationHigh-Voltage Requires Reliable Decisions Instead of Assumptions
High-voltage power electronics are developing from today's typical 400 to 500 V in the direction of 800 to 1200 V. As voltages increase, fault patterns and risk profiles change. Breakdowns, leakage currents and moisture-related effects can no longer be reliably derived from low-voltage empirical values.
Insulation coordination is the design framework for this. Distances between conductive materials must be dimensioned in such a way that insulation failure during operation is avoided. The degree of contamination is defined for this purpose. It describes how conductive impurities can become and how often condensation can be expected in the application. One key question is therefore crucial: How can the appropriate pollution degree be substantiated when empirical values alone are no longer sufficient and compliance with DIN EN IEC 60664-1 must be demonstrated?
When Insulation Coordination Becomes a Project Risk
In practice, the issue usually becomes urgent when one of the following points applies:
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OEM requires a comprehensible justification of degree of contamination as well as clearances and creepage distances
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Current failures or field anomalies such as sporadic breakdowns, tracking, leakage current indications
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Conversion to 800 V platforms, new materials, new environmental profiles
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Uncertainty as to whether assumptions about contamination and humidity during operation are realistic
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Need for releasable documentation for internal committees and audit situations
If you want to classify the topic with certainty, talk to us.
isolation coordinationObjective of the Risk Assessment
The aim is not an additional theory, but rather a decision-making template that can be used in the project. Specifically, three questions are answered:
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How high is the actual risk of insulation failure under real conditions
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What causes drive the risk in the specific assembly
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Which measures reduce the risk demonstrably and with reasonable effort
The result is a decision template for insulation coordination that can be approved internally and used with OEMs.
What is Evaluated in Practice
A robust justification of the degree of contamination requires an assessment of the relevant risk drivers, not a broad treatise. Essentially, there are three points that often interact in high-voltage applications:
Technical Cleanliness
Particles and residues that can affect insulation distances
Ionic Contamination
Ionic residues which, in combination with moisture, can promote conductive films and leakage currents
Coating
The actual protective effect of a coating, including possible weak points
The evaluation is based on targeted analysis and validation, for example fritting voltage analysis, ion chromatography and coating testing, and is consistently geared towards informative value for insulation coordination.
ProcedureQuickly to Reliable Statements
To turn the risk assessment into a decision template for isolation coordination, the procedure follows three clear steps:
Step 1: Clarify the context
Voltage level, assembly structure, operating environment, failure patterns, requirements and existing specifications.
Step 2: Evaluate the risk drivers
Targeted analysis and evaluation of the relevant drivers with a focus on informative value for insulation coordination.
Step 3: Decision and measures
Risk classification, prioritized remedial measures and clear recommendations for short-term impact and sustainable protection.
ResultReportable, Decision-Relevant, Implementable
You receive compact, comprehensible documentation that summarizes the following points:
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Risk classification in relation to breakdown, leakage current and moisture effects
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Justification of which assumptions regarding the degree of contamination are viable
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Prioritized measures for risk reduction along the process, cleaning and protection concept
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Concrete next steps for verification after implementation
This provides a reliable basis for ensuring insulation coordination complies with standards, reducing failures and reliably determining risks.
Getting startedTalk to us
When insulation coordination becomes a project topic due to OEM requirements, current failures or a high-voltage changeover, it makes sense to get started quickly. An initial meeting clarifies the objective, framework conditions and the quickest way to make reliable statements. Alternatively, a sample assessment can serve as a structured starting point.
Request a consultation
Confidential and structured. With NDA on request.
Whitepaper CollectionAnalytical Appreach to Implementing Insulation Coordination
At 400 V to 1200 V, extrapolated low voltage assumptions are no longer sufficient. This white paper explains how pollution degree, contamination, and insulating materials can be assessed using an analytical approach.