Electrical Breakdown Analysis Across Electrode-Gaps for High Voltage Applications

This paper addresses critical electrical breakdown issues observed in high-voltage (HV) systems, particularly at electrode gaps, through both simulation and experimental studies. The research was initiated in response to a problem encountered by a partner company, where sparking and electrical breakdowns were observed while testing electric vehicle (EV) contactors. The sparking caused machine failures and affected nearby equipment, leading to operational disruptions. Previous attempts to mitigate the issue using insulation tape proved ineffective for a long time, highlighting the need for more reliable insulation solutions. The study focuses on identifying effective insulation materials and strategies to prevent sparking and breakdown events during testing. Based on simulation results, optimal insulation materials and coating thicknesses were identified and subsequently validated through experimental work using actual HV electrodes and contractors. By providing insights into the most effective insulation solutions, this research aims to improve the reliability and safety of HV applications while reducing costs associated with trial-and-error testing of insulation materials.