After years of deep technical cultivation and co‑innovation with users, Bepto delivers fast, reliable and scalable customized insulator solutions worldwide.
Short Answer: We strictly implement the ISO 9001:2015 international quality management system, which covers the entire process from design and procurement to production, inspection, and delivery.
Detailed Explanation: We understand that quality is the lifeblood of our company. Our Quality Management System (QMS) is built upon the ISO 9001:2015 standard and certified by an accredited third party. The core of this system is the “process approach” and “risk-based thinking,” ensuring all business activities are controlled. Specifically, it includes: Design and Development Control to ensure products meet performance and reliability requirements from the start; Supplier Management to guarantee the quality of raw materials at the source; Production Process Control through Standard Operating Procedures (SOPs) and Key Process Parameter (KPP) monitoring for product consistency; Inspection and Testing at three key stages: Incoming (IQC), In-Process (IPQC), and Final (FQC); and a Continuous Improvement mechanism through internal audits, management reviews, and customer feedback.
Short Answer: We conduct 100% inspection on all epoxy resin embedded poles, including visual checks, dimensional measurement, X-ray scanning, and partial discharge testing to ensure zero defects.
Detailed Explanation: The epoxy resin embedded pole is the core component of a vacuum circuit breaker, and its quality is directly linked to the safety of the switchgear. Therefore, we implement an extremely rigorous quality control process. During production, we monitor the temperature, pressure, and time curves of the APG process in real-time. After production, every single pole must pass the following tests:
1) Visual and Dimensional Inspection: We use a high-precision CMM machine to check critical dimensions and ensure the surface is free of cracks, voids, or other defects.
2) Internal Structure NDT: We use industrial X-ray equipment to non-destructively inspect the internal structure, ensuring a tight bond between the vacuum interrupter and the epoxy resin and checking for any voids or impurities.
3) Electrical Performance Testing: We conduct Partial Discharge (PD) and Power Frequency Withstand Voltage tests in a shielded room to ensure the PD level is below 5 pC and the withstand voltage meets the IEC 62271-100 standard. Only products that pass all tests are cleared for shipment.
Short Answer: Our switchgear insulators are designed, manufactured, and tested in strict accordance with International Electrotechnical Commission (IEC) standards, such as IEC 60660 and IEC 62231.
Detailed Explanation: To ensure our switchgear insulators are reliable and universally compatible, we adhere to the most authoritative international standards. Design and routine tests are primarily based on IEC 60660:2011 (Insulators – Tests on indoor post insulators of organic material for systems with nominal voltages greater than 1000 V up to 250 kV). This standard specifies the electrical and mechanical performance requirements. Our factory tests include visual inspection, dimensional verification, power frequency withstand voltage test, and cantilever strength test. For new product development or significant design changes, we conduct full type tests, which also include lightning impulse withstand voltage test, damp-heat test, and a test for the material’s Comparative Tracking Index (CTI), to fully verify long-term reliability and performance in harsh environments.
Short Answer: Our Gas Insulated Switchgear (GIS) Bushings are manufactured under an ISO 9001 certified system and can be supplied with a type test certificate from an independent lab like KEMA.
Detailed Explanation: The quality of our GIS bushings is assured by a multi-layered system. First, the entire production process is monitored under our ISO 9001 certified QMS, guaranteeing process stability and product consistency. Second, the product design and performance fully comply with the requirements of IEC 62271-203 (Gas-insulated metal-enclosed switchgear for rated voltages above 52 kV) and IEC 60137 (Insulated bushings for alternating voltages above 1000 V). To further demonstrate their superior quality, we can provide a complete type test report for specific models, issued by an internationally recognized independent third-party laboratory such as KEMA (Netherlands) or TÜV (Germany). This report serves as authoritative proof that the product’s performance—covering temperature rise, partial discharge, lightning impulse, short-time current, and all other key indicators—meets leading international benchmarks.
Short Answer: We conduct strict Incoming Quality Control (IQC) on every batch of epoxy resin, testing for viscosity, epoxy value, color, moisture content, and glass transition temperature (Tg).
Detailed Explanation: As the core material for solid insulation products, the quality of epoxy resin is paramount. Our IQC lab is equipped with advanced instruments to ensure every incoming batch meets our internal standards.
1)Viscosity Test: Measured with a rotational viscometer at a constant temperature to ensure the resin has good flowability for the APG process.
2)Epoxy Value & Chlorine Content Analysis: Accurately determined through chemical titration, these are key indicators of the resin’s purity and reactivity.
3)Glass Transition Temperature (Tg) Test: We use Differential Scanning Calorimetry (DSC) to measure the Tg of the cured material. This is a critical parameter that determines the product’s maximum operating temperature and thermal stability. Only raw materials with all indicators within the specified range are approved for production, ensuring quality from the very beginning.
Short Answer: We offer an 18-month quality assurance period. For any product that fails due to a manufacturing defect within this time, we promise to provide a free replacement and cover the shipping costs.
Detailed Explanation: We stand behind the quality of our products with a solid warranty. Our standard quality assurance period is 18 months from the date of shipment. If a client discovers any product defect attributable to our manufacturing process or materials during this period, they simply need to provide relevant photos, videos, or test data. Our quality team will respond within 48 hours to initiate an investigation. Once the responsibility is confirmed to be ours, we will immediately start a rapid replacement process, providing a brand-new, qualified product free of charge and bearing all associated shipping costs to the client’s designated location. Our goal is not only to solve the problem but also to minimize any impact on the client’s project schedule and maintain their trust in our brand.
Short Answer: We conduct partial discharge (PD) testing inside a professional electromagnetic shielded room using a high-precision PD detector, applying test voltage according to the IEC 60270 standard.
Detailed Explanation: Partial discharge (PD) is the most critical indicator of the internal insulation quality of high-voltage components. Our PD tests are performed in a purpose-built electromagnetic shielded room with a background noise level below 1 pC to eliminate external interference and ensure test accuracy. We use a digital PD detection system from a world-renowned brand. During the test, following the procedure outlined in IEC 60270, the product (e.g., an embedded pole or sensor) is connected to a corona-free high-voltage source. The voltage is slowly raised to the specified test level (typically 1.2 times the rated phase voltage) and maintained for 60 seconds while we monitor the PD level. We strictly ensure that the PD level for all our products is well below the standard requirement of 10 pC, typically controlling it to under 5 pC, with some high-end products achieving levels below 3 pC.
Short Answer: Our quality lab is equipped with advanced instruments including an X-ray inspection system, a CMM machine, a partial discharge test system, a power frequency withstand tester, and a material tensile testing machine.
Detailed Explanation: To achieve comprehensive quality control, we have invested in a wide range of advanced testing equipment. Our lab’s primary instruments include:
1) YXLON X-ray Real-time Imaging System (Germany): Used for non-destructive testing of the internal structure of insulation parts to check for defects like voids, cracks, or impurities.
2) Hexagon Coordinate Measuring Machine (CMM) (Sweden): For high-precision dimensional measurement of products to ensure they meet drawing tolerances.
3) Haefely Partial Discharge Test System (Switzerland): For highly sensitive PD detection inside our shielded room.
4) Power Frequency and Lightning Impulse High Voltage Generators: To simulate normal and over-voltage conditions in the power grid and test the product’s dielectric strength.
5) MTS Material Testing Machine (USA): Used to test the tensile, bending, and compressive strength of our epoxy composite materials to verify their mechanical properties.
Short Answer: The dimensional accuracy of a switchgear contact box is critical as it directly affects the clearance with the circuit breaker, the insulation distance, and the overall assembly and safety of the switchgear.
Detailed Explanation: A switchgear contact box (or tulip contact assembly) serves not only as a conductive part but also provides insulation and support. Its dimensional accuracy is decisive for the switchgear’s performance.
1)Mating Precision: The inner diameter of the box must perfectly match the circuit breaker’s conductive rod to prevent poor contact, overheating, or arcing.
2)Insulation Distance: Its external dimensions and mounting hole positions determine the electrical clearance and creepage distance between live parts and the earthed metal enclosure. Any deviation could lead to an insulation breakdown.
3)Interchangeability: Standardized dimensional accuracy ensures high interchangeability, facilitating mass assembly and on-site replacement for our clients. Therefore, we use a CMM to perform 100% inspection of critical dimensions for every batch of contact boxes, ensuring tolerances are controlled within ±0.1mm.
Short Answer: We achieve quality consistency in mass production through Standard Operating Procedures (SOPs), real-time monitoring of key parameters (SPC), regular equipment maintenance, and strict final product sampling.
Detailed Explanation: Maintaining high quality consistency during mass production is a core challenge of our quality management. We achieve this through several methods:
1) Standard Operating Procedures (SOPs): We have developed detailed SOPs for every process step (material mixing, preheating, injection, curing, finishing), ensuring all operators follow the same standards.
2) Statistical Process Control (SPC): We collect and monitor real-time data for key parameters in the APG process, such as mold temperature, injection pressure, and holding time. SPC charts help us detect minor process deviations early and make adjustments to prevent batch defects.
3) Preventive Maintenance (PM): We have a strict equipment maintenance schedule for the regular calibration and servicing of APG machines, molds, and testing instruments to keep them in optimal condition.
4) AQL Sampling Inspection: In addition to 100% inspection of critical electrical properties, we perform a final sampling inspection for appearance, dimensions, etc., based on the AQL (Acceptable Quality Level) standard as a final quality gate.
Short Answer: X-ray inspection is a non-destructive testing method used to check for internal defects that are invisible to the naked eye, such as voids, cracks, impurities, or misaligned metal inserts.
Detailed Explanation: For solid insulation materials like epoxy resin, the integrity of the internal structure directly determines the electrical performance and long-term reliability. The purpose of X-ray inspection is to “see through” the product. For example, in an epoxy embedded pole, a tiny air gap between the vacuum interrupter and the epoxy can trigger partial discharge under high voltage, eventually leading to insulation failure. Similarly, conductive impurities or internal micro-cracks formed during curing can create points of high electrical stress, becoming potential failure sources. With our real-time X-ray imaging system, we can clearly identify these millimeter- or even micron-level internal flaws without damaging the product, allowing us to cull defective units and ensure that every product delivered to our clients is internally “pure” and structurally sound.
Short Answer: We ensure the quality of our SF6 series insulation parts by using materials compatible with high-purity SF6, conducting rigorous gas leakage tests, and performing partial discharge inspections.
Detailed Explanation: SF6 Gas Insulated Switchgear (GIS) places special demands on its insulation components. We guarantee their quality in three ways:
1) Material Compatibility: The epoxy resin formulation we use has undergone rigorous testing to prove its excellent long-term chemical stability and low-adsorption properties in an SF6 environment, ensuring it won’t degrade from reactions with SF6 by-products.
2) Gas Tightness: For sealed components like GIS bushings, we perform helium mass spectrometry leak detection to ensure the leakage rate is far below the IEC standard of 0.1% per year, preventing environmental impact and equipment failure.
3) Electrical Performance: All SF6 series insulation parts undergo partial discharge and withstand voltage tests in a simulated SF6 gas pressure environment, as the gas characteristics influence discharge behavior. This guarantees the product has an adequate safety margin under actual operating conditions.
Short Answer: Our insulation materials have a Comparative Tracking Index (CTI) of 600V (PLC 0), representing the highest resistance to tracking, which is crucial for preventing equipment short circuits.
Detailed Explanation: The Comparative Tracking Index (CTI), tested according to IEC 60112, is a critical measure of an insulating material’s ability to resist the formation of conductive tracks on its surface in the presence of moisture and contamination. When an insulator’s surface becomes contaminated and damp, a conductive path can form, leading to small electrical arcs. Over time, these arcs can carbonize the material, creating a permanent conductive “track” that can cause a phase-to-phase or phase-to-ground short circuit. A higher CTI value indicates better resistance to tracking. Through an optimized formulation, particularly the addition of high-performance inorganic fillers, our epoxy composite materials consistently achieve the highest CTI rating of over 600V. This is especially important for switchgear operating outdoors or in highly humid and polluted environments, as it significantly enhances operational safety and reliability.
Short Answer: We ensure complete epoxy resin curing and eliminate internal stress by precisely controlling the heating curve, holding time, and cooling rate in our curing ovens, followed by a post-curing process.
Detailed Explanation: The epoxy resin curing process is a critical stage that determines the final mechanical and electrical properties of the product. Incomplete curing or rapid temperature changes can create significant internal stress, leading to cracking or performance degradation. We use PLC-controlled industrial ovens to precisely manage the entire heat treatment cycle.
Heating Stage: We use a stepped, slow heating ramp to ensure uniform temperature distribution throughout the product.
Holding Stage: Based on the product’s size and complexity, we maintain the optimal curing temperature (e.g., 140°C) for a specified duration (8-12 hours) to ensure the chemical cross-linking reaction is complete.
Cooling Stage: We use a program-controlled slow cooling rate to prevent internal stress caused by uneven thermal contraction. Additionally, all products undergo a “post-curing” treatment in a separate oven after demolding to further stabilize the molecular structure, maximizing mechanical strength and thermal stability.
Short Answer: Insulation failure is primarily caused by electrical, thermal, mechanical, and environmental stresses. We prevent these through optimized design, high-quality materials, and strict quality control.
Detailed Explanation: Insulation failure is a complex process that we work to prevent at the source.
1) Electrical Stress (e.g., Partial Discharge): We use software like Ansys for electric field simulation to optimize product design and eliminate points of high electrical stress. Our APG process and X-ray inspection ensure no internal voids, fundamentally suppressing PD inception.
2) Thermal Stress (e.g., aging, cracking): We select epoxy formulations with a high glass transition temperature (Tg) to provide a sufficient thermal margin. Our precisely controlled curing and post-curing processes minimize internal stress, preventing thermal shock cracking.
3) Mechanical Stress: We verify material properties with our MTS testing machine and ensure product designs can withstand mechanical loads from seismic events and short-circuit forces.
4) Environmental Stress (e.g., flashover): We design products with an appropriate creepage distance and use high-CTI materials to resist the effects of moisture and pollution.
Short Answer: For our eco-friendly gas series parts, we have added material compatibility tests with the new gases and adjusted electrical test parameters to match their unique insulation properties.
Detailed Explanation: Eco-friendly gases (such as dry air or N₂/O₂ mixtures) have different insulation and chemical properties than SF6, so our quality control process is adapted accordingly. Material Compatibility Testing is a new, critical step. We expose our epoxy material samples to the target eco-friendly gas and its arc by-products for extended periods, then test for any changes in mechanical strength and electrical performance to ensure no corrosion or accelerated aging occurs. In Electrical Testing, since the dielectric strength of these gases is typically lower than SF6, we redefine the power frequency and lightning impulse test voltage levels based on the new operating pressure and insulation coordination requirements. We also apply stricter controls on partial discharge levels to guarantee an adequate safety margin in the new gas environment. These additional tests ensure the long-term reliability of our eco-friendly product series.
Short Answer: A type test report is the ultimate validation of a product’s overall performance by an independent authority, proving its design and manufacturing capabilities meet international standards and bolstering supplier credibility.
Detailed Explanation: While routine tests (factory tests) ensure the basic quality of each individual product, a type test is a comprehensive examination of the product’s design. It is conducted by an independent, accredited third-party laboratory (like KEMA, CESI, or IPH), and the tests are far more rigorous and extensive than routine tests. They include a full suite of dielectric, temperature rise, short-time and peak withstand current, mechanical, and environmental tests. A complete type test report signifies that the product’s design, materials, and manufacturing process have successfully passed simulations of the most severe operating conditions. For a buyer, it serves as the gold standard of product quality and is an objective measure of a supplier’s technical strength, R&D capabilities, and quality management level, significantly reducing procurement risk.
Short Answer: We assign a unique serial number to each product or batch and use an MES system to record its complete quality data, from raw materials and production parameters to final test results.
Detailed Explanation: We have implemented a comprehensive quality data traceability system. Every key insulation component is assigned a unique QR code or serial number at the beginning of its production. This “ID” follows the product throughout its lifecycle. Our Manufacturing Execution System (MES) automatically links this serial number to all relevant quality information, including: raw material batch numbers (traceable back to the supplier), production information (operator, equipment ID, APG process curves), in-process inspection records, and final FQC test data (e.g., PD value, withstand voltage results, dimensional reports). If a customer has a query about a specific product, they simply provide the serial number, and we can retrieve its complete “quality file” within minutes. This allows for rapid problem identification, root cause analysis, and the implementation of effective corrective and preventive actions.
Short Answer: Our internal quality standard is much stricter than the industry requirement; we mandate that partial discharge for all high-voltage insulation parts must be less than 5 picocoulombs (pC) at 1.2 times the rated voltage.
Detailed Explanation: International standards (like IEC) often specify an acceptable partial discharge level of 10 pC or 20 pC for medium- and high-voltage insulation components. However, we understand that PD is a primary cause of progressive insulation aging and eventual failure. Therefore, we have set a more stringent internal control standard. By using high-quality raw materials, optimized mold designs, and precision APG process control, we can consistently keep the PD level of most products below 5 pC. For highly critical applications (such as switchgear for high-reliability data centers), we can even supply premium products with a guaranteed PD level below 3 pC. This commitment to quality, while increasing our production costs, provides our customers with a higher safety margin and a longer product service life, which we believe is a worthwhile investment.
Short Answer: All our critical testing instruments are calibrated annually by an accredited third-party agency (CNAS equivalent) and are subject to a strict internal schedule of regular checks and preventive maintenance.
Detailed Explanation: The accuracy of test data is the cornerstone of quality control. To ensure this, we have established a comprehensive metrology management system.
1)External Calibration: We contract with professional, nationally accredited metrology labs to perform a full calibration of all our measurement and testing equipment used for final product acceptance (e.g., high-voltage dividers, PD calibrators, digital multimeters, calipers, tensile testers) on an annual basis. A certificate of calibration is issued for each instrument.
2)Internal Verification: Between external calibrations, our equipment managers use calibrated reference standards to perform internal checks on a quarterly or monthly basis to monitor for any drift.
3)Preventive Maintenance: We have detailed maintenance procedures for each precision instrument, which are carried out by designated personnel to ensure the equipment is always in optimal working condition. These measures guarantee that every test report we issue is accurate, reliable, and traceable.
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