Testing the inter-turn insulation performance of the vehicle airflow solenoid valve coil is crucial for ensuring reliable operation of the solenoid valve. The quality of the inter-turn insulation directly affects the electromagnetic conversion efficiency and lifespan of the vehicle airflow solenoid valve coil. Insulation failure can lead to inter-turn short circuits, localized overheating, or even equipment burnout, consequently causing abnormal airflow control and affecting engine performance. Therefore, a systematic test using specialized methods and equipment is necessary.
The core principle of the test is to simulate extreme operating conditions using high-voltage pulse technology to expose potential insulation defects. In practice, an inter-turn insulation tester is used. This device injects thousands of volts of high-voltage pulses into the vehicle airflow solenoid valve coil under test and compares the damped oscillation waveforms generated by the tested coil with those of a standard coil. High waveform overlap indicates good insulation performance; if the waveform shows amplitude attenuation, frequency shift, or a decrease in the number of oscillations, it suggests an inter-turn short circuit, poor contact, or insulation degradation. This method can accurately locate minute defects invisible to the naked eye, preventing equipment malfunctions caused by localized overheating or breakdown during operation.
Adequate preparation is essential before testing. First, select an appropriate testing instrument based on the voltage level of the vehicle airflow solenoid valve coil. The test voltage range is typically 0.5kV to 6kV, and the instrument parameters must cover 2 to 4 times the equipment's operating voltage. Second, clean the surface of the vehicle airflow solenoid valve coil to remove oil, dust, and other impurities to avoid interfering with the test results. Furthermore, disconnect the vehicle airflow solenoid valve coil from the vehicle's electrical system to prevent high-voltage pulses from damaging other components. The testing environment should be dry and free from strong electromagnetic interference to ensure accurate instrument readings.
The testing procedure must be strictly standardized. Connect the vehicle airflow solenoid valve coil to the instrument's test terminal, set the test voltage, and start the test. During the test, observe the waveform changes and record the data. If the waveform overlap is below the set threshold, it is considered unqualified, and the vehicle airflow solenoid valve coil must be further disassembled to check for short circuits or insulation aging. For qualified vehicle air flow solenoid valve coils, the testing date and parameters must be marked, and a quality record must be established for traceability. After testing, the instrument must be calibrated and reset to ensure the accuracy of subsequent tests.
Safety precautions must be taken during testing. Although the instantaneous high voltage output of the inter-turn tester is extremely short-lived, there is still a risk of electric shock. Operators must wear insulated gloves, goggles, and other protective equipment to avoid direct contact with high-voltage components. Warning signs must be set up in the testing area to prevent unauthorized personnel from approaching. If a severe short circuit or smoke is found in the vehicle air flow solenoid valve coil during testing, the power should be immediately cut off and the site evacuated. The equipment should be allowed to cool down before further action is taken.
In addition to the high-voltage pulse method, other testing methods can be used as supplementary tools. For example, the inter-turn insulation condition can be indirectly assessed by measuring parameters such as the DC resistance and insulation resistance of the vehicle air flow solenoid valve coil. If the DC resistance deviates significantly from the standard value, it may indicate an inter-turn short circuit; if the insulation resistance is too low, it indicates that the insulation material is damp or aged. In addition, temperature detection can be used in conjunction with other methods. After the solenoid valve has been operating for a period of time, the surface of the vehicle air flow solenoid valve coil can be touched. If the temperature is too high, it may be due to localized overheating caused by an inter-turn short circuit, requiring further investigation.
The judgment of test results requires a comprehensive assessment of multiple indicators. If the high-voltage pulse test waveform is qualified, and parameters such as DC resistance and insulation resistance are within the normal range, and the vehicle air flow solenoid valve coil shows no abnormalities such as burning or damage, then the inter-turn insulation performance can be determined to be good. If any test item fails, the vehicle air flow solenoid valve coil must be repaired or replaced. For repaired vehicle air flow solenoid valve coils, a full-item test must be performed again to ensure that its performance is restored to the standard requirements.
Regularly testing the inter-turn insulation performance of the vehicle air flow solenoid valve coil can effectively prevent equipment failure and extend its service life. It is recommended to conduct a basic test every quarter. For vehicles frequently used in extremely cold, high-temperature, or high-humidity environments, the testing cycle should be shortened. Through scientific testing and maintenance, it can be ensured that the solenoid valve is always in optimal working condition, providing a reliable guarantee for vehicle airflow control.
