High-voltage power supplies for grid lightning impulse and surge protection testing serve as core experimental equipment for insulation performance evaluation, lightning protection component verification and surge protective device (SPD) certification. They are widely applied in lightning impulse withstand tests, switching impulse tests and surge immunity tests for transmission & transformation equipment, power electronic devices, surge arresters, SPDs, transformers, circuit breakers and insulators. As the core module of impulse test systems, the high-voltage pulse power supply generates standard lightning impulse, switching impulse and surge waveforms. Its pulse amplitude accuracy, waveform parameter consistency, high-energy output capability, long-term operational stability and repetition frequency directly determine test precision, repeatability and the effectiveness of insulation qualification for grid equipment.
Lightning and surge testing imposes extreme technical requirements far exceeding conventional power supplies: 1.High-precision standard waveform output: Fully compliant with GB/T 16927.1 and IEC standards. Standard lightning impulse 1.2/50μs: front time tolerance ≤±30%, time-to-half-value ≤±20%, peak voltage ≤±3%. Switching impulse 250/2500μs; surge waveforms 8/20μs current and 10/700μs voltage per GB/T 17626.5. Pulse amplitude repeatability ≤±0.5% to ensure accurate, reproducible test results. 2.Ultra-high voltage & massive energy output: Output voltage covers 1kV~2400kV for UHV equipment; output current reaches 1kA~200kA for high-power arresters and SPDs. Single pulse energy up to 1MJ with overall energy efficiency ≥85%, satisfying extreme UHV and high-current surge test scenarios. 3.Nanosecond-level rising-edge control & adaptive waveform tuning: Precise tuning of 1.2μs wavefront to compensate distortion caused by capacitive, inductive and resistive test objects. Supports customized non-standard impulse waveforms for special research and certification needs. 4.High repetition frequency & continuous operational stability: Continuous pulse output up to 1 shot per second for thousands of impulses in durability and batch production tests. Waveform stability deviation ≤±1% during long-term operation without thermal degradation or component failure. 5.Ultra-high electrical isolation & comprehensive safety protection: Isolation withstand ≥2× maximum output voltage; non-bypass multi-level hardware protection including overvoltage, overcurrent, short circuit, test-object breakdown, interlock and emergency stop to eliminate UHV safety hazards. 6.Extreme EMC immunity & environmental adaptability: Stable operation under severe electromagnetic impulse fields in laboratories; compliant with GB/T 17626 and GB/T 16927.1. Operating temperature: −10℃~+50℃, humidity 10%~90% RH for indoor and on-site outdoor testing. 7.Intelligent control & traceable data management: Fully automatic testing, real-time waveform acquisition, auto-calibration, data storage, report generation; supporting IEC 61850, Modbus for integration with laboratory automation systems. 8.Metrology traceability & legal compliance: Fully aligned with JJG 755 and JJG 994 verification regulations; complete traceability chain ensuring test data validity for official type approval and metrological certification.
This methodology establishes a full-process technical framework covering high-precision pulse topology, high-energy output optimization, standard waveform closed-loop control, strong EMC protection and metrology compliance. Adopting the universal architecture: Marx multi-stage capacitor charge-discharge topology + FPGA nanosecond synchronous triggering + closed-loop waveform calibration, integrated with full-channel electromagnetic shielding and metrology-grade measurement systems. It eliminates traditional limitations such as low waveform accuracy, poor repeatability, weak anti-interference performance and insufficient energy capability for UHV testing. The Marx topology charges capacitors in parallel and discharges them in series, generating ultra-high impulse voltage without extreme primary charging voltage. Symmetric structural design ensures excellent waveform consistency, while nanosecond synchronous triggering guarantees precise multi-stage switch synchronization for ultra-stable standard pulses.
1.High-precision standard waveform topology design: •Optimized Marx multi-stage charge-discharge structure accurately generates 1.2/50μs, 250/2500μs, 8/20μs and 10/700μs standard waveforms. Flexible stage configuration supports 1kV~2400kV output with symmetric layout for superior waveform symmetry and stability. •High-energy low-inductance pulse capacitors (energy density ≥0.5J/cm³) withstand ultra-large current discharge up to 200kA and single pulse energy up to 1MJ. Constant current & constant voltage charging achieves charging efficiency ≥90% and overall system efficiency ≥85%. Ultra-low-inductance busbar layout minimizes parasitic inductance for high-current surge testing. •Nanosecond wavefront control with low-inductance gas switches and coaxial structure keeps total inductance at nH level. Adjustable front/tail resistors and tuning inductors compensate load distortion for capacitive, inductive and resistive specimens; supports customized special impulse waveforms.
2.Full-digital nanosecond synchronous triggering & control system: •FPGA-based synchronous controller with high-stability oven-controlled crystal oscillator achieves clock jitter ≤10ns, independent adjustable delay ≤10ns and overall synchronization accuracy ≤50ns, ensuring simultaneous conduction of all Marx switches to avoid waveform distortion. •DSP high-precision CC/CV charging control maintains charging voltage accuracy ≤±0.2% and repeatability ≤±0.1%, guaranteeing pulse amplitude repeatability ≤±0.5%. •High-speed waveform acquisition system (200MHz bandwidth, 1GS/s sampling rate) with precision voltage dividers and Rogowski coils realizes metrology-grade measurement. Closed-loop auto-calibration dynamically adjusts charging voltage, trigger delay and tuning parameters to correct load-induced distortion automatically. •Three-layer FPGA+DSP+IPC control realizes full-automatic testing: parameter configuration, auto-charging, waveform calibration, pulse emission, data recording and intelligent report generation.
3.Strong electromagnetic shielding & anti-interference design: •Full fiber-optic isolation between high-voltage impulse circuits and control systems completely cuts off conductive interference paths; fiber isolation withstand ≥100kVAC ensures stable triggering without misfire or leakage. Control & measurement power adopts battery power and optical isolation to isolate grid noise. •Double-layer shielding enclosures (inner permalloy magnetic shielding, outer aluminum electric shielding) achieve shielding efficiency ≥100dB with fully welded seamless structure. Double-armored shielded cables suppress coupled electromagnetic radiation. •Three-level transient surge protection on all ports: gas discharge tubes for primary energy absorption, decoupling filtering for intermediate suppression, ultra-fast TVS for nanosecond clamping. Multi-stage EMI filtering provides ≥120dB interference suppression from 150kHz to 100MHz. •Independent earthing systems for protection, measurement, control and shielding converge to a dedicated laboratory grounding grid with grounding resistance ≤0.5Ω, preventing ground potential rise during high-energy discharge.
4.High reliability & long-lifetime engineering: •Premium pulse capacitors endure more than 10⁴ full-energy discharges with ≥20-year lifespan; high-reliability gas/vacuum switches achieve electrical life ≥10⁵ operations. All components adopt extreme derating: voltage stress ≤50%, current stress ≤40% of rated values. •Fanless natural cooling with no moving parts realizes maintenance-free full-lifecycle operation. Real-time online monitoring tracks capacitance, switch status, temperature and insulation for early aging warning and predictive maintenance. •Strict component screening and thermal cycling; full-unit aging with over 1000 full-energy continuous impulse tests ensures stable long-term performance after delivery. •Non-bypass dual hardware & software protection: overvoltage, overcurrent, short circuit, overtemperature, under air pressure and specimen breakdown protection respond within 1μs to cut off charging instantly and protect equipment and test objects.
5.Ultra-high isolation & full safety protection system: •Dual insulation with charging transformer isolation + multi-stage reinforced insulation achieves isolation withstand ≥2× maximum output and impulse withstand ≥3× maximum output. All high-voltage parts adopt uniform electric field optimization to avoid corona discharge and partial breakdown. •Five-level non-bypass safety interlock: hardware emergency stop, door interlock, grounding interlock, zone isolation and permission control. High-voltage charging is prohibited if any interlock condition fails. •Redundant independent discharge circuits release residual high voltage to safe levels within 100ms during emergency stop or test completion to eliminate residual charge risks. •High-voltage live indication, acousto-optic alarm and infrared human intrusion detection ensure personnel safety; all high-voltage components adopt fully enclosed structure with no exposed live parts.
6.Wide load adaptation & distortion compensation: •Adaptive loop parameter design covers specimen capacitance from 10pF to 10μF with load regulation ≤±3%, compatible with insulators, breakers, arresters and SPDs of various characteristics. Fast-switchable tuning components enable rapid waveform optimization. •Finite-element-based load-waveform model pre-adjusts parameters; real-time closed-loop correction eliminates distortion automatically without manual intervention. •Supports customized non-standard pulses including chopped waves, steep-front impulses, oscillating waves and multi-pulse sequences; polarity switching for positive/negative impulse output.
7.Intelligent operation & traceable data management: •Industrial HMI and upper-computer software support visual parameter setting, real-time waveform display and fully automatic testing; three operation modes: manual, semi-auto and full-auto with multi-level access permission control. •Long-term non-tamper data storage (>10 years) records waveform data, parameters, environment, operator and timestamp. Complete metrology traceability supports official test report generation in PDF/Excel formats. •Rich interfaces (RS485, Ethernet, GPIB) support Modbus, SCPI and IEC 61850 for seamless integration with automated laboratory management and remote unmanned operation.
8.Metrology compliance & full-scenario standard adaptation: •Fully compliant with GB/T 16927.1, GB/T 17626.5, JJG 755, JJG 994 and IEC 60060-1, passing official metrological verification and type evaluation. •Covers all mainstream tests: lightning impulse, switching impulse, arrester discharge, SPD surge, insulator pollution and power electronic surge immunity; adaptable to laboratory, on-site substation and field emergency testing scenarios with flexible voltage/current/window configuration.
In summary, this integrated design framework solves core bottlenecks of traditional impulse power supplies: low waveform accuracy, poor repeatability, weak EMC performance and insufficient energy capacity for UHV applications. It realizes 1kV~2400kV ultra-wide voltage output, 200kA large current, 1MJ single pulse energy, ≤50ns multi-switch synchronization, ≤±0.5% amplitude repeatability and full metrology traceability. Widely used for UHV transmission equipment lightning tests, surge arrester certification and power system insulation evaluation, it provides critical independent core technology for domestic high-voltage test equipment localization and performance upgrading.