In today’s rapidly developing new energy industry, the safety of battery packs, as the core power source, is paramount. Air tightness testing is a crucial process for ensuring battery pack safety and preventing the intrusion of moisture and dust. However, in our discussions with numerous frontline battery repair and quality inspection personnel, we found that they are generally troubled by several testing challenges: mismatched interface models leading to leaks, inadequate sealing causing misjudgments, and cumbersome and inefficient traditional tooling operations. These problems not only affect production schedules but also create potential safety hazards.
As a company deeply rooted in new energy technology solutions, Guheng Energy understands the root causes of these pain points. Today, we will start from practical problems and delve into why knob-type inflator clamps are gradually becoming the industry’s preferred solution for air tightness testing challenges, and introduce how we empower your testing work through innovative product design.
The Challenges of Battery Pack Air Tightness Testing
Ideally, air tightness testing should be a fast, accurate, and reliable process. However, reality is often harsh, and operators frequently face the following challenges:
The prevalence of air leakage problems
- Common operational errors: Battery pack explosion-proof valve interfaces vary widely. For example, the common PBA2K-60G dual-ear explosion-proof valve, if used with universal or incompatible tooling, can easily lead to minute leaks due to incomplete contact surfaces. These leaks are difficult to detect statically but directly cause results failure during dynamic testing, requiring repeated testing and consuming significant time.
- Impact on battery safety: Even a single undetected minute leak can become a channel for moisture intrusion throughout the battery pack’s lifespan, causing serious safety incidents such as cell corrosion and short circuits, with unimaginable consequences.
The challenges of incompatible tooling
- Inefficiency due to incompatible interfaces: Repair workshops or production lines often need to handle multiple battery pack models. Without dedicated tooling, technicians need to frequently change and adjust fixtures, and even make temporary modifications. The entire preparation work is time-consuming and labor-intensive, severely slowing down the testing progress.
- Inspection errors caused by poor sealing: Besides interface mismatch, issues such as worn seals and loose fixings in traditional tooling can introduce leakage points “not related to the battery pack itself,” distorting the inspection data and failing to accurately reflect the battery pack’s quality. This may lead to misjudging qualified products or missing unqualified products.
How can the knob-type inflation clamp break the deadlock?
Addressing the above pain points, Guheng Energy’s G11 knob-type inflation clamp offers a fundamental solution. It’s not just a tool, but an integrated and efficient solution for airtightness testing of explosion-proof valves.
Innovative Design: Plug and Inflation in One
- Rapid Sealing Principle: The core innovation of the G11 clamp lies in integrating the plug and inflation channel into one unit. During operation, simply align the clamp with the PBA2K-60G double-ear explosion-proof valve and rotate the handle to simultaneously establish the sealing and inflation channels. This design eliminates cumbersome multi-step operations, simplifying the sealing process to its extreme, achieving “one-step” completion.
- Precise Fit: This clamp is custom-designed for the PBA2K-60G double-ear explosion-proof valve. Its sealing structure perfectly matches the contours of the valve’s double ears, ensuring even force distribution during tightening, thus achieving a 360° seal without dead angles and fundamentally eliminating the risk of leakage due to incompatible tooling.
Strong and Durable with Plug and Play
- Long-Term Reliability of the Metal Housing: Unlike ordinary plastic tooling, the G11 knob-type inflatable clamp is constructed with an all-metal housing, capable of withstanding high-intensity, high-frequency daily use. It is impact-resistant and corrosion-resistant, effectively extending the tool’s lifespan and reducing tool wear and tear costs during long-term operation.
- Convenience of StandardΦ8 Air Tube Connector: The clamp comes standard with an industry-standard Φ8 air tube connector. Users only need to connect the air tube to begin work, achieving true “plug and play.” This greatly improves the flexibility of equipment deployment, enabling rapid setup of testing systems in both fixed workstations and mobile testing scenarios.
The Practical Application Value of Guheng Energy’s G11 Rotary Inflation Clamp
Transforming innovative design into actual productivity is our ultimate pursuit.
Significantly Improved Testing Efficiency
In practical applications, using the G11 clamp reduces preparation time for a single airtightness test by approximately 50%. The cumbersome process of multiple attempts and wrapping PTFE tape to ensure a seal, previously required, is replaced by a simple rotation. This allows technicians to complete more testing tasks per unit of time, directly increasing throughput in the workshop or production line.
Greatly Enhanced Testing Reliability
Due to the stable and reliable sealing effect, the accuracy of test results is significantly improved. This means a significant reduction in false positives and false negatives, providing a solid safety and quality guarantee for every battery pack leaving the factory. Simultaneously, its robust design ensures long-term performance stability, avoiding interference from fluctuations in the tool’s own condition.
Building a Complete Testing Solution
At Guheng Energy, we understand that an efficient and reliable testing process requires more than just a single excellent tool; it necessitates a complete system support. The G11 rotary inflator clamp seamlessly integrates with our other professional equipment, creating a complete testing ecosystem. For example, you can connect it to our QMM series airtightness tester. This tester features a high-precision pressure sensor and advanced leak detection algorithms, providing fast and accurate quantitative test results. The entire testing system is reliably connected via a dedicated battery pack testing harness from Guheng Energy, ensuring stable signal and gas path transmission. From tooling and equipment to connectors, we offer a one-stop solution, ensuring reliability and efficiency at every stage of your testing process.
Industry Trends and Future Outlook
With the continued expansion of the new energy vehicle and energy storage markets, the requirements for efficiency, accuracy, and standardization in battery safety testing will only increase. The specialized and integrated tooling concept represented by the rotary inflator clamp is an inevitable trend in future industry development. Guheng Energy will continue to focus on the real pain points of frontline users, using innovative products like the G11 rotary inflator clamp as a foundation for continuous iteration. We are actively collecting user feedback and are committed to developing dedicated fixtures compatible with more interface models. We are also exploring the possibility of integrating smart sensors into the tooling, contributing to a smarter and more digitalized future of battery maintenance.
FAQ
Q: What types of battery packs are suitable for the knob-type inflation fixture?
A: It is mainly for battery packs equipped with standard explosion-proof valves. Guheng Energy’s G11 knob-type inflation fixture is specifically designed for PBA2K-60G dual-ear explosion-proof valves, which are widely used in battery packs of various electric vehicles and energy storage power stations. Before use, please confirm that your battery pack’s explosion-proof valve model is compatible.
Q: How to avoid air leakage during battery pack airtightness testing?
A: First, using dedicated tooling that is perfectly matched to the explosion-proof valve model is crucial. For example, the G11 fixture ensures a proper seal from the outset. Second, regularly check the tooling’s sealing rings for wear and keep the interfaces clean. Finally, ensure that the air hoses and connectors connected to airtightness testing equipment are tight and leak-free.
Q: How durable is Guheng Energy’s knob-type inflation clamp?
A: Extremely durable. The G11 knob-type inflation clamp features an all-metal shell design, making it robust and able to withstand frequent use in testing workshops and a certain degree of accidental impact. Its internal core components have also undergone careful selection and durability testing, ensuring the product’s stability and reliability under long-term use.
Q: Why does it improve testing efficiency?
A: Because it simplifies multiple steps, such as finding the plug, installing the sealing ring, and connecting the inflation tube, into a single “align-rotate” action. This “two-in-one” design eliminates cumbersome preparation processes, significantly reducing the time spent on a single operation and greatly improving the work efficiency of technicians.
