
Reliability testing refers to activities carried out to evaluate whether a product can maintain its functional reliability throughout its specified service life, under all anticipated environments such as use, transportation, or storage.
| Introduction to Reliability Testing
Reliability testing refers to activities carried out to evaluate whether a product can maintain its functional reliability throughout its specified service life, under all anticipated environments such as use, transportation, or storage. It involves subjecting the product to natural or artificially created environmental conditions in order to assess its performance under actual usage, transport, and storage environments, while also analyzing the extent and mechanisms of environmental influences.
| Purpose of Reliability Testing
By using various kinds of environmental test equipment to simulate climatic conditions such as high temperature, low temperature, high temperature with high humidity, and temperature variations, the product’s response to usage environments can be accelerated. This process validates whether the product meets the intended quality targets set during research, design, and manufacturing, thereby enabling an overall evaluation to determine the product’s reliability lifespan.
| Necessity of Reliability Testing
Reliability testing helps to identify product weaknesses, confirm process and manufacturing defects, and provide suggestions for improvements. It assists enterprises in enhancing process levels, extending product lifespan, and improving quality. Furthermore, it offers technical support for R&D and production, enabling the creation of high-quality products and enhancing a company’s market competitiveness.
大类 Major Categories |
项目介绍 Project Introduction |
标准与设备 Standards and Equipment |
击穿电压 Breakdown voltage |
在规定的试验条件下,试样发生击穿时的电压,单位KV The breakdown voltage of the specimen under specified test conditions, expressed in kilovolts (kV). |
参考标准: Reference standard: ASTM D149-09(2013) GB/T 1408.1-2006 IEC 60243-1-2013 ASTM D1000-10 GB/T 4677-2002 |
介电强度 Dielectric strength |
在规定的试验条件下,击穿电压与施加电压的两电极之间距离(即样品厚度)的商。单位KV/mm The ratio of breakdown voltage to the distance between the two electrodes to which the voltage is applied (i.e., the specimen thickness) under specified test conditions. Unit: kV/mm |
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介电常数 Dielectric constant |
电容器的电极之间及电极周围的空间全部充以绝缘材料时,其电容Cx与同样电极构成的真空电容C0之比εr=Cx/C0 When the space between the electrodes of a capacitor, as well as the surrounding area, is completely filled with insulating material, the ratio of its capacitance Cx to the capacitance C0 of the same electrodes in a vacuum is defined as the relative permittivity: εr=Cx/C0. |
参考标准: Reference standard: GB/T 1409-2006 GB/T 1693-2007 ASTM D150-11 |
介质损耗 Dielectric Loss |
由绝缘材料作为介质的电容器上锁施加的电压与由此而产生的电流之间的相位差的余角为介质损耗角,其正切值为介质损耗因数。 For a capacitor that uses an insulating material as the dielectric, the complementary angle of the phase difference between the applied voltage and the resulting current is called the dielectric loss angle. The tangent of this angle is the dielectric loss factor. |
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体积电阻率 Volume resistivity |
在绝缘材料里面的主流电场强度和稳态电流密度之商,即单位体积内的体积电阻;单位为Ω·cm或Ω·m The ratio of the main electric field strength to the steady-state current density inside the insulating material, i.e., the volume resistivity per unit volume. The unit is expressed in Ω·cm or Ω·m. |
参考标准: Reference standard: GB/T 3048.3-2007 GB/T 1410-2006 GB/T 15662-1995 ASTM D257-14 |
表面电阻率 Surface Resistivity |
在绝缘材料的表面层里的直流电场强度与线电流密度之商,即单位面积内的表面电阻;单位为Ω/sq The ratio of the DC electric field strength within the surface layer of the insulating material to the line current density, i.e., the surface resistance per unit area. The unit is expressed in Ω/sq. |
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耐电压 Withstand voltage |
耐电压是一项检测绝缘耐受工作电压或过电压的能力和检查电气设备绝缘制造或检修质量的实验,需要使用耐电压测试仪。 耐压测试仪是测量耐电压强度的仪器,它可以直观、准确、快速、可靠地测试各种被测对象的耐受电压、击穿电压、漏电流等电气安全性能指标.它主要达到如下目的: Withstand voltage testing is an experiment used to evaluate the capability of insulation to endure operating voltage or overvoltage, as well as to inspect the manufacturing or maintenance quality of electrical equipment insulation. This requires the use of a withstand voltage tester. A withstand voltage tester is an instrument for measuring dielectric strength. It provides a direct, accurate, rapid, and reliable test of various electrical safety performance indicators such as withstand voltage, breakdown voltage, and leakage current of the test object. Its main purposes are as follows: a.检测绝缘耐受工作电压或过电压的能力。 a. To test the ability of insulation to withstand operating voltage or overvoltage. b.检查电气设备绝缘制造或检修质量。 b. To inspect the quality of insulation manufacturing or maintenance of electrical equipment. c.排除因原材料、加工或运输对绝缘的损伤,降低产品早期失效率。 c. Eliminate insulation damage caused by raw materials, processing, or transportation, thereby reducing early product failure rates. d.检验绝缘的电气间隙和爬电距离。 d. Verify the electrical clearance and creepage distance of insulation. |
参考标准: Reference standard: EIA-364-20C 设备参数: Equipment Parameter: Agilent/34420A EIA-364-20C |
接触电阻 Contact resistance |
接触电阻,对导体间呈现的电阻称为接触电阻。 Contact resistance refers to the resistance exhibited between conductors at their point of contact. 一般要求接触电阻在10-20 mohm以下。有的开关则要求在100-500uohm以下。有些电路对接触电阻的变化很敏感。应该指出, 开关的接触电阻是开关在若干次的接触中的所允许的接触电阻的最大值。 在电路板上是专指金手指与连接器之接触点,当电流通过时所呈现的电阻之谓。为了减少金属表面氧化物的生成,通常阳性的金手指部份,及连接器的阴性卡夹子皆需镀以金属,以抑抵其“接载电阻”的发生。其他电器品的插头挤入插座中,或导针与其接座间也都有接触电阻存在。 In general, contact resistance is required to be below 10–20 milliohms. Certain switches require it to be below 100–500 microohms. Some circuits are highly sensitive to variations in contact resistance. It should be noted that the contact resistance of a switch refers to the maximum permissible contact resistance during multiple actuations of the switch. On printed circuit boards, this specifically refers to the contact resistance at the interface between the gold finger and the connector when current flows through. To reduce the formation of metal surface oxides, the male gold finger portion and the female connector clips are usually plated with metal to suppress the occurrence of “contact load resistance.” Other electrical devices, such as plugs inserted into sockets or pins inserted into their mating receptacles, also exhibit contact resistance. |
参考标准: Reference standard: EIA-364-06C 设备参数: Equipment Parameter: Agilent/34420A EIA-364-06C |
绝缘电阻 Insulation resistance |
现代生活日新月异,人们一刻也离不开电。在用电过程中就存在着用电安全问题,在电器设备中,例如电机、电缆、家用电器等。 Modern life is evolving rapidly, and people cannot live without electricity even for a moment. During electricity usage, electrical safety issues inherently exist in equipment such as motors, cables, and household appliances. 绝缘物在规定条件下的直流电阻。 The DC resistance of an insulating material under specified conditions. 绝缘电阻是电气设备和电气线路最基本的绝缘指标。对于低压电气装置的交接试验,常温下电动机、配电设备和配电线路的绝缘电阻不应低于0.5MΩ(对于运行中的设备和线路,绝缘电阻不应低于1MΩ/kV)。低压电器及其连接电缆和二次回路的绝缘电阻一般不应低于1MΩ;在比较潮湿的环境不应低于0.5MΩ;二次回路小母线的绝缘电阻不应低于10MΩ。I类手持电动工具的绝缘电阻不应低于2MΩ。 绝缘电阻:加直流电压于电介质,经过一定时间极化过程结束后,流过电介质的泄漏电流对应的电阻称绝缘电阻。 Insulation resistance is the most fundamental insulation parameter of electrical equipment and electrical circuits. For handover testing of low-voltage electrical installations, the insulation resistance of motors, distribution equipment, and distribution lines at room temperature shall not be less than 0.5 MΩ (for equipment and lines in operation, the insulation resistance shall not be less than 1 MΩ/kV). The insulation resistance of low-voltage electrical devices, their connecting cables, and secondary circuits shall generally not be less than 1 MΩ; in relatively humid environments, it shall not be less than 0.5 MΩ; the insulation resistance of secondary circuit busbars shall not be less than 10 MΩ. For Class I handheld power tools, the insulation resistance shall not be less than 2 MΩ. Insulation resistance refers to the resistance corresponding to the leakage current flowing through a dielectric after the application of DC voltage and the completion of a certain polarization period. |
参考标准: Reference standard: EIA-364-21C 设备参数: Equipment Parameter: Good Will Instrument (Taiwan) / GPT-9803 台湾固纬/GPT-9803 EIA-364-21C |
温升 Temperature rise |
温升是指电子电气设备中的各个部件高出环境的温度。 Temperature rise refers to the extent to which the temperature of each component in electrical and electronic equipment exceeds the ambient temperature. 导体通流后产生电流热效应,随着时间的推移,导体表面的温度不断地上升直至稳定。稳定的条件是在3个小时内前后温差不超过2℃,此时测得导体表面的温度为此导体的最终温度,温度的单位为度(℃)。上升的温度中超过周围空气的温度(环境温度)的这一部分温度称为温升,温升的单位为开氏(K)。有些关于温升方面的文章和试验报告及试题中,经常把温升的单位写成(℃),单位用度(℃)来表示温升是不妥当的。应该用(K/W)来表示。为验证电子产品的使用寿命、稳定性等特性,通常会测试其重要元件(IC芯片等)的温升,将被测设备置于高于其额定工作温度(T=25℃)的某一特定温度(T=70℃)下运行,稳定后记录其元件高于环境温度的温升,验证此产品的设计是否合理。 When current flows through a conductor, the resulting joule heating effect causes the conductor’s surface temperature to rise continuously over time until it reaches a stable state. The condition of stability is defined as when the temperature variation within three hours does not exceed 2 °C. At this point, the measured surface temperature of the conductor is considered its final temperature, expressed in degrees Celsius (°C). The portion of the elevated temperature that exceeds the ambient air temperature (environmental temperature) is called the temperature rise. The unit of temperature rise is Kelvin (K). In some articles, test reports, and exam questions related to temperature rise, the unit of temperature rise is often incorrectly written as (°C). Using degrees Celsius (°C) to represent temperature rise is inappropriate. It should be expressed in (K/W). To verify the service life, stability, and other performance characteristics of electronic products, the temperature rise of critical components (such as IC chips) is usually tested. The device under test is operated at a specific temperature (T = 70 °C) that is higher than its rated operating temperature (T = 25 °C). Once stabilized, the temperature rise of the component above the ambient temperature is recorded to validate whether the product’s design is reasonable. 电气类产品中:电动机的额定温升,是指在设计规定的环境温度(十40℃)下,电动机绕组的最高允许温升,它取决于绕组的绝缘等级。温升取决于电动机运行中发热情况和散热情况。常根据温升判断电动机散热是否正常。电动机温度是指电动机各部分实际发热温度,它对电动机的绝缘材影响很大,温度过高会使绝缘老化缩短电动机寿命,甚至导致绝缘破坏·为使绝缘不致老化和破坏,对电动机绕组等各部分温度作了一不定期的限制,这个温度限制就是电动机的允许温度。 In electrical products, the rated temperature rise of a motor refers to the maximum permissible temperature rise of the motor windings under the design-specified ambient temperature (40 °C). This limit is determined by the insulation class of the windings. The temperature rise depends on both the heating generated during motor operation and the effectiveness of its cooling. The normality of motor cooling performance is often assessed based on its temperature rise. The motor temperature refers to the actual heating temperature of each part of the motor. It has a significant impact on the insulation material of the motor. Excessive temperature will accelerate insulation aging, shorten motor service life, and may even cause insulation failure. To prevent premature insulation aging or breakdown, temperature limits are imposed on the windings and other motor components. This temperature limit is defined as the permissible temperature of the motor. |
参考标准: Reference standard: EIA-364-70B 设备参数: Equipment Parameter: Agilent/34970 EIA-364-70B |