Why aging is an essential part of BAM Single Phase High-Voltage Film Capacitor production​

​
In the production process of BAM single phase high-voltage film capacitor, aging is a critical part that profoundly affects the final quality and performance of the product. This process is not a simple operation step, but a comprehensive inspection and optimization process of capacitors based on rigorous scientific principles and long-term practical experience. Its importance runs through the entire production cycle and subsequent application of capacitors. ​
Aging puts the capacitor under specific temperature, humidity and voltage conditions for a period of time, with the aim of stabilizing various physical and chemical processes inside the capacitor. From a microscopic perspective, the dielectric material, electrode material and the interaction between the components inside the capacitor have not completely reached a stable state after production is completed. The polypropylene film dielectric may have microscopic stress unevenness during the manufacturing process, and there may also be some subtle defects or unstable interfaces at the junction of the metallized electrode and the film. These potential problems may not be immediately apparent under normal working conditions, but over time and environmental changes, they may cause performance degradation or even failure.​
Through aging treatment, under specific temperature conditions, the thermal motion of the molecules in the capacitor's internal materials intensifies, and the original microscopic stress is released and redistributed, making the structure of the dielectric material more stable. In a high humidity environment, the state of the capacitor in a humid working environment is simulated to test its insulation performance and moisture resistance to prevent problems such as insulation degradation and leakage caused by moisture intrusion. Applying a certain voltage simulates the electrical environment of the capacitor in actual work, allowing the electric field distribution inside the capacitor to fully function, so that potential problems such as partial discharge are exposed in advance. ​
During the aging process, real-time monitoring of various performance indicators of the capacitor is an important means to ensure product quality. As one of the key performance indicators of the capacitor, real-time monitoring can promptly detect capacitance fluctuations caused by material changes and electrode contact problems during the aging process. If the capacitance changes abnormally, it may mean that there are problems such as dielectric aging and electrode oxidation inside the capacitor, which need further investigation and treatment. The loss tangent value reflects the energy loss of the capacitor during operation. By monitoring this indicator, it can be determined whether the loss characteristics of the dielectric inside the capacitor have changed, and whether there are factors such as dielectric aging and moisture that affect the loss.​
Insulation resistance monitoring is also crucial, as it is directly related to the insulation performance and safety of capacitors. During the aging process, if the insulation resistance decreases, it may indicate that the insulating medium of the capacitor is damaged, damp, or has conductive impurities, and must be screened and repaired in time. Through real-time monitoring of these performance indicators, the performance status of each capacitor can be accurately judged, and those early failure products that have exposed problems during the aging process and do not meet quality standards can be screened out. ​
If the screened early failure products are directly put into use without aging treatment, they may fail in a short time. In the power factor compensation application of the power system, the failed capacitor may not be able to effectively compensate for the reactive power, resulting in a decrease in the system power factor, increased line loss, and even causing overload operation of the power equipment. In the motor starting link of industrial equipment, the failed capacitor may not provide enough reactive power, making it difficult to start the motor, causing equipment startup failure and affecting production progress. After aging treatment and screening, the retained capacitors have higher quality reliability and stability. ​
These high-quality capacitors that have undergone aging treatment can bring significant benefits to users after being put into the market and actual application scenarios. In a long-term power system, stable and reliable capacitors can continuously and efficiently perform power factor compensation and voltage regulation, reduce system operation losses, improve the utilization rate of power equipment, and reduce maintenance costs and power outage maintenance time. In the field of industrial production, stable capacitors ensure the normal operation of equipment such as motors and variable frequency speed regulation systems, improve production efficiency, reduce the risk of equipment downtime due to capacitor failure, and create more economic benefits for enterprises. ​
From the perspective of production enterprises, strict implementation of the aging process will help improve the reputation of the company's product quality. High-quality products can enhance the competitiveness of enterprises in the market, attract more customers and orders, and promote the sustainable development of enterprises. The screening of early failed products during the aging process avoids the increase in after-sales maintenance and replacement costs due to product quality problems, optimizes the company's production resource allocation, and improves production efficiency.