HIOKI Launches DC Hipot Tester ST5680

Battery quality proven through extensive international standards-compliant testing.

HIOKI has launched the DC Hipot tester ST5680 for the safety inspection process of battery modules. The DC Hipot test is one of the electrical safety tests in the module production of LIBs (lithium-ion batteries). The required test conditions depend on the standards required for each battery. The DC Hipot tester ST5680 has the specifications to comply with a wide range of international standards. It has the performance to comply with a wide range of DC Hipot tests and insulation resistance tests, as well as a wide variety of features to prove battery quality. Hioki contributes to high-quality, safe battery production by providing reliable testing.


Promote the use of safe electric vehicles

Efforts toward a circular economy are accelerating in all fields in order to pass on limited resources to the next generation. In the automotive industry, the transition to electric vehicles is being driven rapidly around the world with the goal of decarbonizing the industry. Electric vehicles are driven by clean electrical energy that does not emit CO2 during operation. While LIBs can store a large amount of electricity, they also have the risk of electric shock and fire in the event of a failure. In order to enhance the safety of electric vehicles, high-quality and high-reliability are required for in-vehicle components. In particular, since batteries are key components, their safety and quality control are extremely important. International safety standards have been developed to share international requirements for battery safety quality. Hioki is launching the DC Hipot tester ST5680 to promote the use of safe electric vehicles with the aim of decarbonization.


Testing of batteries with increasingly higher voltages

The exterior parts of the battery module are designed to not allow electricity to flow (insulated). However, scratches or the introduction of foreign contaminants that occur during the battery production process cause electricity to flow where it should not, leading to accidents. DC Hipot tests check for these defects by applying high voltages to the test object. These tests are required by a wide range of standards. In particular, they are almost always performed in safety inspections for electrical products. In conventional DC Hipot testing, momentary arcing caused by small scratches inside the battery or contamination in the insulation area could not be judged as a definite defect. However, such potential defects can degrade the battery in a shorter time than expected by design and can cause accidents such as electric shock and fire. The DC Hipot tester ST5680 supports DC Hipot testing of battery products with increasingly higher voltages. Test voltage monitoring enables detection of arcing and recording of waveforms. By recording not only the numerical test results but also the waveforms, production quality can be assured and the cause of problems can be traced. The production of safe and reliable batteries contributes to the popularization of electric vehicles.



1. Proof of Insulation Performance with Waveforms and Numerical Data

The DC Hipot tester ST5680 is capable of DC withstand voltage and insulation resistance testing based on a wide range of international safety standards. Batteries are judged not only with numerical values, but also with the waveform display of output voltage and leakage current during the test. The displayed waveform on the main unit monitor enables analysis of the cause of failure based on fluctuations during the test that cannot be determined numerically.

2. Preventing the market release of minute defective products due to arc discharge

If there is contamination inside the battery, arc discharge can occur during DC withstand voltage testing. The DC Hipot Tester ST5680’s Arc Discharge Detection feature identifies batteries with minute insulation defects caused by arc discharge. Screening for high quality batteries contributes to improved reliability.

3. Preventing delayed defective rejections due to misjudgment

Faulty equipment wiring in the DC Hipot test can cause false positive results even when the test object is not in contact with the equipment. False positive test results can cause defective products to be released into the market. The DC Hipot Tester ST5680 prevents false positive results through its contact check function.


Main Applications

DC Hipot testing in battery cell production lines for LIBs
DC Hipot testing of finished battery modules


For more information, contact CN Rood!