To ensure optimal performance and reliability, all components of the vacuum interrupter must be thoroughly cleaned before assembly. Contaminants can emit gases into the vacuum envelope, compromising the high vacuum required for effective arc extinction. To achieve a high breakdown voltage, the components are assembled in a cleanroom environment where dust and particulate matter are strictly controlled. This stringent control over environmental conditions is essential for maintaining the integrity of the vacuum and the dielectric strength of the interrupter.

Before assembly, the surfaces of the components undergo electroplating to ensure a smooth and uniform finish. Each component is then subjected to an optical inspection to verify the surface consistency and quality. This step is critical for identifying any defects or irregularities that could affect the performance of the interrupter.

The assembly of the vacuum interrupter is performed under air-conditioned cleanroom conditions to maintain the highest level of cleanliness. High-vacuum solder is applied at the joints of the components to ensure a hermetic seal. The parts are carefully aligned and fixed to ensure precise assembly. This meticulous process is essential for achieving the high quality and maximum possible ratings up to 100 kA, as specified by the IEC/IEEE 62271-37-013 standard.

Initially, subassemblies of vacuum interrupters were brazed together in a hydrogen-atmosphere furnace. During this process, a tube connected to the interior of the interrupter was used to evacuate the air with an external vacuum pump while the interrupter was maintained at a temperature of approximately 400 °C (752 °F). Since the 1970s, the manufacturing process has evolved to use a high-vacuum brazing furnace that combines brazing and evacuation in a single step. This process involves heating tens or hundreds of interrupters in batches to temperatures up to 900 °C at a pressure of 10−6 mbar. This advanced technique ensures that the interrupters are "sealed for life," meeting the highest quality standards.

Thanks to the fully automated production process, the high quality of the vacuum interrupters can be consistently reproduced at any time. Automation minimizes human error and ensures that each unit meets the same stringent quality criteria, guaranteeing reliable performance and long-term durability.

After assembly, the vacuum interrupters undergo an X-ray evaluation to verify the positions and completeness of the internal components, as well as the quality of the brazing points. This non-destructive testing method ensures that the internal structure of the interrupter is flawless and that all components are properly aligned and securely attached. The X-ray procedure is a critical step in the quality control process, ensuring the high reliability and performance of the vacuum interrupters.

During the formation process, the definitive internal dielectric strength of the vacuum interrupter is established through a series of gradually increasing voltage applications. This step is crucial for conditioning the internal surfaces and materials to withstand high electrical stresses. Subsequently, a lightning impulse voltage test is conducted to verify the dielectric strength. Both the formation and verification processes are performed using voltage levels that exceed those specified in industry standards. This rigorous testing regime provides strong evidence of the high quality and reliability of the vacuum interrupters, ensuring long endurance and high availability in critical electrical applications.

The manufacturing and quality control of vacuum interrupters involve a series of precise and controlled steps, from thorough cleaning and surface finishing to advanced brazing and evacuation techniques. The use of cleanroom conditions, high-vacuum solder, and fully automated production processes ensures that each interrupter meets the highest quality standards. Rigorous testing, including X-ray evaluation and dielectric strength testing, further guarantees the reliability and performance of the vacuum interrupters, making them suitable for demanding high-voltage applications.

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