In the field of battery safety, the most dangerous threats are often the most insidious. A tiny electrolyte leak can cause a multi-million dollar energy storage system to shut down unexpectedly, or create a fire hazard in the chassis of a new energy vehicle. This “invisible leak” cannot be detected by the naked eye, yet it slowly and fatally erodes battery safety. In this article, Guheng Energy will guide you through understanding “electrolyte leakage,” this battery “hidden killer.”

Why is electrolyte leakage a battery “hidden killer”?

Electrolyte leakage usually originates from aging seals, manufacturing defects, or external mechanical damage. Its harm is gradual and insidious, forming a triple threat chain:

First Layer: Hardware Corrosion and Performance Degradation

A small amount of electrolyte leakage will slowly corrode the metal connectors inside the battery, the BMS acquisition harness terminals, and the PCB circuit board, leading to increased contact resistance, signal acquisition distortion, and ultimately causing a systemic decline in battery performance.

The second layer: Insulation failure and internal short circuits

Electrolyte itself is conductive. When it accumulates inside the battery pack, it creates unexpected conductive paths between cells and between modules and the casing, significantly increasing the risk of internal short circuits. This is one of the direct causes of thermal runaway.

The third layer: Chain reaction of thermal runaway

Leaked electrolyte decomposes at high temperatures, producing flammable gases (such as volatile esters like DMC and DEC). Once exposed to an electrical spark or localized high temperature, these gases can easily ignite and explode, and the fire spreads extremely rapidly.

Why have traditional detection methods failed?

Faced with increasingly complex battery pack structures and stringent safety regulations, traditional detection methods have revealed fatal shortcomings:

• Visual inspection: Inadequate: Modern battery packs employ highly integrated designs with complex internal structures. Over 90% of potential leak points are located in blind spots. Micro-level leaks (<1μL/min) are simply undetectable by the naked eye.
• Odor identification: Dangerous and ineffective: Attempting to determine leaks by odor is both unscientific and dangerous. Different electrolyte formulations have similar odors, making misjudgment highly likely; more seriously, direct inhalation of electrolyte volatiles can damage the respiratory tract.
• Pressure holding test: Destructive and inefficient: Traditional airtightness testing, while able to detect obvious leaks, cannot precisely locate the leak point and may cause pressure damage to the battery structure, making it unsuitable for routine maintenance.

Technological Breakthrough: Precise Detection of Micro-Leaks

Guheng Energy’s QMD series portable electrolyte leak tester employs an industry-leading combination of detection technologies, achieving a paradigm shift from “passive repair” to “proactive prevention.”

PID Sensor l

• High-precision PID sensor (photoionization detector).
• Detection sensitivity reaches 0.1ppm (parts per million concentration level).
• Specifically optimized for electrolyte volatiles (esters, fluorides, etc.).
• Response time <3 seconds, enabling real-time monitoring.

Exclusive Pressure Control Technology

• Automatic Pressure Regulation: The system intelligently controls the pressure within the testing chamber, simulating the actual operating pressure difference environment of a battery.
• Rapid Balancing Mechanism: Pressure balancing is completed within 30 seconds, significantly improving detection efficiency.
• Precise Sampling System: Targeted and quantitative gas sampling is performed on suspicious areas, avoiding environmental interference.

Intelligent Detection Process

Start Equipment → Set Parameters → Probe Scan → Real-time Monitoring → Exceedance Alarm → Data Upload

Guheng Energy QMD Series: Industrial-Grade Leak Detection Solution

Core Advantages Matrix

Feature Category	Technical Specifications	Application Value
Detection Accuracy	Adjustable 0.1-10ppm, false alarm rate <1%	Achieve early warning and prevent problems before they occur
Response Speed	<3-second real-time response	Improve inspection efficiency by more than 3 times
Compatibility	Supports mainstream electrolytes such as LFP/NCM/sodium batteries	Multi-purpose, reduces procurement costs
Intelligent	Supports MES system integration and QR code management	Builds a traceable quality system

Modular Design to Meet Diverse Scenarios

Production Line Quality Control Module

• Barcode Scanner Integration: Automatically associates cell/module ID.
• Linkage with EOL Testing Station: Real-time upload of leakage data to MES.
• Automatic pass/fail sorting signal output.

On-Site Maintenance and Diagnostic Module

• Portable Design: Weight <2kg, operable with one hand.
• Long-range battery: 8 hours of continuous operation.
• Anti-interference design: Stable operation in complex industrial environments.

Cloud data management module (optional)

• Test data synchronization to the cloud.
• Leakage trend analysis and early warning.
• Remote expert diagnostic support.

From detection to prevention: In-depth analysis of application scenarios

Battery OEMs: Full-process monitoring of the production line

Setting up inspection points in key processes such as cell liquid filling and sealing, module packaging, and PACK assembly to achieve:

• Early detection of process defects, reducing rework costs.
• Establishing a “leakage fingerprint” file for each battery.
• Providing data support for supplier quality management.

Energy storage power stations: Preventive maintenance system

Establishing tiered inspection standards:

• Routine inspection: Monthly general inspection of key points in the battery compartment.
• Specialized inspection: Increased inspection frequency during high-temperature seasons and after frequent charging and discharging.
• Accident investigation: Rapidly locating the leak source after system alarm.

After-sales service center: Rapid diagnostic tools

• Single-vehicle inspection completed within 10 minutes.
• Accurately distinguish between “true leaks” and “false alarms”.
• Generate visualized detection reports to assist in claims settlement and liability determination.

Conclusion: Choose Professionalism, Build a Safety Defense Line

Electrolyte leak detection has evolved from an “optional item” to a “safety necessity.” Based on over a decade of battery testing technology accumulation, Guheng Energy has developed the QMD series as “not just a tool, but a solution.” We provide a complete service encompassing “hardware equipment + testing process + data analysis” to help customers establish a comprehensive leak prevention system. Safety is paramount; prevention is better than cure. Let professional testing technology become the most reliable outpost in your battery safety management.

FAQ

Q: What is the specific detection accuracy of the QMD series? How is long-term accuracy guaranteed?

A: The standard detection range is 0.1-100ppm, with a maximum accuracy of 0.1ppm. The equipment needs to be calibrated every 6 months using standard gas. We provide calibration services and an annual maintenance plan to ensure measurement traceability.

Q: Does it support the detection of different electrolyte formulations (such as LFP and NCM)?

A: Yes. The instrument features multiple built-in detection modes, which can be switched via software to adapt to the main volatile characteristic spectra of different electrolytes. For special formulations, we support customized sensor calibration.

Q: How does the equipment interface with existing quality management systems?

A: It provides multiple interfaces including RS485, CAN, Ethernet, and Wi-Fi, supporting seamless integration with MES and QMS systems. It comes standard with the Modbus protocol, and communication protocols can also be customized according to customer systems.

Q: Will detection be affected in noisy, dusty industrial environments?

A: The equipment has an IP54 protection rating, and the sensor inlet is equipped with a multi-layer filtration system to effectively isolate dust and oil mist interference. A dedicated environmental compensation algorithm eliminates the effects of temperature and humidity fluctuations.

Q: What are the core advantages of the QMD series compared to similar products on the market?

A: Three major differentiating advantages: unique air pressure control + PID sensing technology for more accurate detection; complete barcode scanning, data management, and cloud functions; and scene adaptability and modular design that allows for flexible configuration to meet different needs such as production lines and maintenance.