Insulation resistance testing helps verify that transformer insulation is clean, dry, and suitable for the required voltage stress. BaoHui Tech uses insulation checks together with hipot, creepage, clearance, visual inspection, and process control for custom transformers used in industrial power and electronics applications.
What Insulation Resistance Measures
Insulation resistance testing measures leakage through or across insulating materials under a DC test voltage. Low readings can indicate moisture, contamination, damaged insulation, poor spacing, or unsuitable materials.
The result depends on test voltage, temperature, humidity, insulation geometry, and surface condition. It should be interpreted in context rather than as a standalone number.
Test Details to Define
BaoHui Tech recommends defining insulation resistance requirements early when safety or high-voltage reliability matters.
- Test voltage, test duration, measurement points, and acceptance limit
- Primary-to-secondary, winding-to-core, shield-to-winding, and terminal-to-case checks
- Humidity, cleanliness, varnish or potting condition, and drying process
- Creepage, clearance, insulation tape, sleeving, and bobbin structure
- Relationship with hipot testing, visual inspection, and production records
Using Results for Quality Control
Insulation resistance can help identify process drift, moisture exposure, or handling damage. It is especially useful when combined with batch traceability and material control.
For repeat production, the test method and acceptance limits should be included in the drawing or inspection plan.
BaoHui Tech Engineering Support
BaoHui Tech manufactures custom high frequency transformers, power transformers, inductors, EMI filters, and inverter magnetic components with insulation testing aligned to application requirements.
FAQ
Useful inputs include topology, voltage, current, power level, operating frequency, waveform, insulation and safety requirements, thermal environment, dimensions, mounting method, target tests, and expected production volume.
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