en.Wedoany.com Reported - Pickering Electronics, a UK-based manufacturer of high-performance reed relays, has released an application guide for engineers involved in high-voltage measurement and insulation testing of electric vehicles (EVs) and charging stations. The guide, titled "Reed Relays for EV and Chargepoint Testing," explains why high-isolation reed relays are an ideal choice for instruments and test equipment used to measure high voltages and verify the integrity of electrical insulation.
The electrification of powertrains in electric vehicles and hybrid electric vehicles (HEVs and PHEVs) relies on high-voltage batteries, battery management systems (BMS), power inverters, and powerful electric motors. These high-voltage components are of a "floating" design, meaning their power terminals are not grounded to the chassis. Consequently, all high-voltage components and high-current carrying cables require robust insulation. The design and manufacturing of EVs, as well as the supply of supporting charging stations, demand specialized equipment and processes to ensure safety. As the number of EVs increases, similar equipment and processes will also be needed for their maintenance, repair, and recycling.
Robert King, Product Manager for Reed Relays at Pickering Electronics, stated that EVs and charging stations present demanding high-voltage environments for instrumentation and test equipment. Reed relays, with their compact size, high isolation, and low leakage characteristics, are well-suited for these test applications where both safety and measurement accuracy are critical. Their mechanical contact path can switch AC or DC while helping to minimize leakage, preventing interference with insulation measurements.
The guide explains that EV power lines and high-voltage components are heavily insulated to prevent short circuits to grounded objects and ensure safety. In addition to measuring high voltages (both DC and AC), it is essential to confirm the integrity of the insulation surrounding high-voltage components and cables. High-voltage and insulation testing is also required during the product development of charging stations and after they are put into service.
King added that it is necessary to develop instruments capable of safely measuring high voltages and performing insulation tests in charging stations, and these instruments will require switching functionality. Reed relays can achieve leakage currents below 1 nA and isolation open-circuit voltages of several thousand volts in a compact package. The reed switch contacts are hermetically sealed, which helps protect them from contamination and oxidation compared to open electromechanical contacts.
Reed relays feature the following characteristics: hermetic sealing to prevent dust and moisture from contacting the contacts; the ability to withstand high switching voltages and isolation open-circuit voltages; extremely low leakage, supporting precise sensing and monitoring; electrical isolation, helping to protect instrument electronics; and fast, compact operation capable of millions or even billions of operations.
Pickering is regarded as a leader in the high-end reed relay market, thanks to its innovative product design, high-performance components, and superior quality control. All of the company's relays use instrument-grade reed switches for stable, long-life operation, along with formerless coil construction and its patented SoftCenter technology, which enhances mechanical stability. Mu-metal shielding enables high packaging density with minimal magnetic interference, and every relay undergoes 100% testing to ensure consistent quality.
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