For each of the research and innovation team, the most important thing beyond implementing novel features to the product is high quality and safety. This remind us of the lesson of the Samsung Note 7 incidence and why the safety is most important. In addition, especially now the adapter as the main power source is increased output power to provide faster charging speed. If a high-power adapter has not been properly designed or tested, it will bring serious electrical and fire hazards. Therefore, engineers must study relevant safety standards and understand the test requirements to create high-quality charging products.
The fundamental safety testing continues to be the key
For information and communication technology charging products, they should comply with IEC 62368. Therefore, the fast-charging adapter must be certificated by conducting multiple required electrical safety tests, including Hipot, ground bond, insulation resistance, and leakage current test. In the following, we will introduce each testing requirement and method:
- Hipot Test
Apply around 3kVac on the input terminal and connect the output terminal’s data and GND pins. The testing duration is 60 seconds. The pass requirement is the adapter should withstand this high voltage without breakdown. - Ground Bond Test
To ensure the fault current can flow to the ground properly, use twice of rated current or 25A (Pick the higher one. Usually use 25A) to conduct the test. Inject this current to the ground terminal for 120 seconds. The resistance between this point and chassis should not excess 100mΩ. - Insulation Resistance
Use 500Vdc to test the adapter’s insulation capability, the insulation resistance should not be less than 2MΩ. - Leakage Current
To ensure the leakage current won’t hurt the operator under different seminars, use 110% of rated voltage (usually use 110 to 264 Vac). The leakage current should be no more than 5mA.
ESA Series Electrical Safety Compliance Analyzer combines all standards-required safety tests in one tester. It is capable of AC/DC Hipot, insulation resistance, AC ground bond, leakage current test, etc. The IEC 62368 leakage current test required a measuring device (MD) that is built-in, saving your time on the testing setup. With the 1905 Touch Current Testing Fixture Socket (Shown in Figure 1), repetitive wiring steps can be reduced and make the electrical safety tests easier. This is most manufacturers’ first choice of electrical safety tester.
Figure1: ESA and DUT Connection
Along with the high-performance smartphone launching and fast charging feature benefit working on the go, the high-power adapter demand is expected to increase. How to ensure safety, accuracy and enhance productivity and efficiency are also the biggest challenge for most manufacturers. In the production line, the adapter required a higher testing voltage to conduct the Hipot test to ensure product quality and end-user safety. However, the repeated setting is extremely time consuming and personal error can cause misjudgment and potential risk.
To increase production line testing efficiency and maintain products’ high quality, many manufacturers select the ESM-500 MultiPRO Electrical Safety Platform. Define your own solution to the adapter production line tests. Serie-parallel multiple platforms synchronized test to improve testing efficiency. Different from traditional tests that multiple devices can be tested at a time. ESM-500 has independent display testing results for each channel. When productivity increases, the misjudgment greatly reduces. As the best choice of the production line, ESM-500 adopts a modular design. Quickly eliminate the system fault and greatly reduce maintenance and spare parts costs.
eec an Ikonix brand has more than 80 years of industrial experience, we deeply understand what challenges that you may face. Therefore, we work closely with leading companies and labs to provide everyone with the proper solutions. We have successfully helped many customers to solve their testing challenges. If you have any electrical safety tests questions, please contact us now.
