Against the backdrop of explosive growth in the energy storage industry, the safety and long lifespan of energy storage systems have become core concerns for brand owners. However, in actual energy storage battery maintenance , many operation and maintenance teams often focus on monitoring electrical performance parameters (such as voltage and internal resistance), while neglecting a fatal hidden danger: the failure of the battery pack’s airtightness.
Even the slightest leak in the battery casing or sealing structure can allow moisture and external impurities to penetrate the battery, leading to decreased electrochemical performance, thermal runaway risks, and even fires. This drawback, stemming from neglecting airtightness testing, is gradually becoming a “hidden killer” in energy storage station operations.
I. The potential threat to energy storage systems from neglecting airtightness testing
During long-term maintenance of energy storage batteries , battery packs often face multiple challenges, including thermal expansion and contraction, vibration, and chemical corrosion. A lack of accurate airtightness testing can lead to the following serious consequences:
1. Moisture intrusion causes insulation failure.
Energy storage power stations are mostly located outdoors. Sealing failure can allow high-humidity air to enter the battery pack, causing condensation to adhere to the surfaces of the cells and high-voltage components. This can range from reducing insulation resistance and triggering alarms to causing short circuits and tripping.
2. Risks of electrolyte leakage and thermal runaway
Battery packs employing highly integrated technologies such as CTP (cell-to-pack) have compact internal structures and stringent heat dissipation requirements. Damage to airtightness may indicate microcracks in the casing. Once the internal electrolyte leaks out and comes into contact with air, it can easily trigger smoke or even a violent fire, causing significant asset losses for the brand owner.
3. Nonlinear decay of service life
Poor sealing can lead to a deterioration of the internal electrochemical reaction environment, accelerating the loss of active materials. This loss is difficult to capture through BMS data in the early stages, but in the later stages of operation, the battery capacity will drop precipitously, severely impacting the ROI (Return on Investment) of the energy storage station.
II. How to maintain the battery?
Effective routine maintenance of energy storage batteries should be based on the principle of “prevention first, inspection second.” In addition to regular equalization maintenance, structural integrity testing (i.e., airtightness) is a safety red line.
Regular electrical performance checks : Use the portable battery pack equalization and maintenance instrument PBM-PW-S-1620 to perform charge and discharge tests and voltage difference repairs on the battery.
Sealing status monitoring : Accurate airtightness testing must be carried out after battery pack installation, maintenance and repair .
Environmental risk assessment : For battery boxes operating under extreme temperature variations, increase the frequency of testing for pressure balancing valves and sealing rings.
Analysis of the Principle of Precision Airtightness Testing
Precise airtightness testing is not simply a matter of visual observation, but a scientific measurement based on the principle of physical pressure difference. Its core logic lies in: by filling the sealed battery pack cavity with dry air at a certain pressure, and going through four stages—”inflation-balancing-detection-venting”—high-precision sensors detect minute changes in internal pressure (pressure drop values) to determine whether a leak exists.
Guheng Energy ‘s precision airtightness testing equipment employs advanced differential pressure sensor technology. Even for extremely small leaks, the system can accurately capture pressure drop data through algorithms and quantify the leakage amount (e.g., ml/min), providing maintenance personnel with intuitive judgment criteria.
IV. Guheng Energy: Your Preferred Supplier of Battery Maintenance and Testing Instruments
As a technology-driven professional manufacturer, Guheng Energy has always been deeply involved in the new energy aftermarket. We understand the pursuit of stability and efficiency by B-end customers, and therefore invest a great deal of effort in product research and development.
1. Technical Highlights: A combination of high precision and ease of use
Our battery maintenance and testing instruments are renowned in the industry for their precision. We have optimized the algorithm for cutting-edge CTP technology, enabling it to adapt to complex testing needs in large-volume, multi-redundant spaces.
2. Core Model Introduction: QMM-AK2-2
Among numerous precision airtightness testing devices , our portable airtightness leak detector QMM-AK2-2 performs exceptionally well:
Portable design : Specifically designed for on-site operation and maintenance of energy storage stations, it is lightweight and easy for single-person operation.
Multi-mode detection : Supports multiple modes such as positive pressure, negative pressure and differential pressure, covering the entire link detection from cell casing to PACK enclosure.
Data traceability : Test results can be automatically saved and uploaded to generate standardized test reports, meeting the stringent quality control requirements of brand owners.
V. Application Scenarios and Solution Cases
Scenario 1: Safety re-inspection of energy storage power stations before and after grid connection
Pain point : During transportation and installation, violent shaking may cause the battery pack sealing bolts to loosen or the rubber strips to become misaligned.
Solution : During the project acceptance phase, an overseas energy storage operator introduced Guheng Energy’s QMM-AK2-2 to conduct random inspections on hundreds of energy storage cabinets.
Results : Three potential sealing failures caused by installation stress were successfully identified and repaired, avoiding the risk of excessive insulation after grid connection.
Scenario 2: Sealing and Closed-Loop Operation After Battery Repair
Pain point : After the battery pack is opened for maintenance (such as replacing the module), the reliability of manual glue application is difficult to guarantee.
Solution : Use the portable airtightness leak tester QMM-AK2-2 to perform an instantaneous differential pressure test after the cover is closed.
Results : Ensuring that every repair kit leaving the factory has the original factory-grade sealing rating significantly reduces customer complaint rates.
VI. Conclusion
In the era of new energy, details determine success or failure. Precise airtightness testing is not only a technical means, but also a reflection of a brand’s responsibility for product safety. Guheng Energy will continue to provide efficient and accurate battery maintenance and testing instruments to ensure the safety of your energy storage projects.
If you are looking for a reliable supplier of battery maintenance and testing equipment, or need more in-depth technical support for energy storage battery maintenance, please contact Guheng Energy immediately .
FAQ
Q: Will airtightness testing damage the internal structure of the battery?
A: No. Guheng Energy’s precise airtightness testing uses low-pressure dry air; the test pressure is far below the shell’s maximum withstand limit, making it a non-destructive test.
Q: Why recommend portable devices instead of desktop lab units?
A: Energy storage stations are widely distributed, and the portable airtightness leak detector QMM-AK2-2 can be directly installed on-site, saving expensive logistics costs and return-to-factory time.
Q: What are the challenges in testing battery packs using CTP technology?
A: CTP technology eliminates the module, resulting in a larger cavity space and a more complex structure. SolidWorks Instruments’ high-precision algorithm can quickly eliminate the effects of thermal drift, ensuring accurate airtightness testing even with large volumes.
Q: Besides airtightness, what other maintenance tools can Guheng provide?
A: We also offer a range of electrical performance testing tools, such as the portable battery pack equalization and maintenance instrument PBM-PW-S-1620, providing complete energy storage battery maintenance technology solutions.
