In the field of new energy vehicle repair, power battery pack repair is one of the most technically demanding and risky aspects. Facing battery packs that often weigh hundreds of kilograms, have intricate structures, and contain high-voltage electricity, a basic yet crucial operation—rotating them 360 degrees—often becomes a major challenge for repair technicians. Traditional methods of “manual labor + brute force” or simple hoisting not only consume a lot of physical strength and slow down the repair process, but also pose significant safety hazards, such as personal injury and secondary damage to the battery pack.
How to overcome this “rotation dilemma” and achieve both safety and efficiency is a hurdle that the industry must overcome to become truly professional. As a manufacturer specializing in new energy service technology solutions and professional tools, Guheng Energy understands this pain point and is committed to providing the ultimate solution through innovative products.
Why is 360-degree rotation essential?
A power battery pack is not a simple monolithic unit; it’s an integrated system comprised of hundreds or even thousands of cells, a complex Battery Management System (BMS), high-voltage wiring, a cooling system, and a robust casing. Faults can occur anywhere.
- Comprehensive Inspection with a Keen Eye: Many defects, such as dents on the bottom of the casing, cracks in welds, and leaks in coolant lines, can only be clearly observed from specific angles. A 360-degree rotation is the first step towardcomprehensive visual inspection and flaw detection, enabling accurate fault diagnosis.
- Standardized Repair at the Golden Angle: Whether disassembling the casing, replacing damaged modules, repairing the busbar high-voltage connector, or applying sealant and conducting airtightness tests, every meticulous step requires the battery pack to be stably fixed at the most ergonomic and easily operable angle. Flexible rotation capability is the cornerstone of ensuring repair quality and smooth workflow.
- Safety Assurance: A runaway battery pack is like a hammer blow. Improper flipping is one of the biggest safety risks in the workshop, easily leading to serious personal injury accidents. It can also cause internal short circuits in battery cells, structural deformation, and even thermal runaway, turning repairs into disasters.
The Pain Points of Traditional Methods: Laborious, Dangerous, and Inefficient
Before the widespread availability of specialized tools, flipping operations in the workshop were often a battle of physical strength and risk.
- PureManual Handling and Flipping: Relies on 4-6 technicians working together, lifting and prying by hand. This process is extremely unstable, prone to causing battery packs to fall due to loss of tension, and lacks precise angle control, placing a huge burden on the technicians’ lumbar spines.
- Overhead Crane/Forklift Assisted Suspension Flipping: After securing the battery pack with slings, an overhead crane is used to lift it and attempt to flip it in the air. The battery pack swings and rotates in the air, making it difficult to control, posing a collision risk, and lacking a reliable intermediate locking function, leaving technicians operating below in constant fear.
However, these methods directly lead to low repair efficiency, soaring labor costs, and high hidden risks—personnel injuries, battery pack damage compensation, and long-term damage to the repair shop’s professional reputation.
A Turnover Frame Designed for Safety and Efficiency
Addressing these pain points, Guheng Energy, with its deep understanding of repair scenarios, has developed a professional-grade battery pack turnover frame. This frame aims to transform the high-risk, high-intensity turnover operation into a safe, easy, and precise standard process. Our main turnover frame models currently include the mobile GHCJ-FZT-YL01 and the floor-standing GHCJ-FZT-YL02. They are not only turnover tools but also stable, multi-functional repair platforms.
How to Achieve Ultimate “Safe Turnover”?
- Robust Foundation, Rock-Stable: The main body of the equipment is welded from high-strength steel pipes, ensuring a stable structure and a maximum load capacity of 1.5 tons, sufficient to handle battery packs from all passenger cars and some commercial vehicles. The spacious base and optimized center of gravity design fundamentally eliminate the possibility of tipping over.
- Multi-level locking, absolutely immovable: This is the core of safety. We employ a multi-level locking system combining mechanical pins and hydraulic assistance. When the battery pack is rotated to any desired working angle, the pins securely lock the rotation axis, ensuring that even during welding, hammering, or other operations, the platform will not slip or swing back, giving technicians complete confidence.
- Flexible clamping, comprehensive protection: The clamps are equipped with adjustable anti-slip, insulating pads, compatible with various battery packs ranging in size from 1200-1900mm wide and 1,000-2,200mm long, effectively protecting the battery pack’s paint and coating while providing electrical isolation to prevent accidental short circuits.
How to significantly improve “repair efficiency”?
- 360°free rotation, precise positioning: The tilting platform allows for more than 360 degrees of free rotation, with angle reference via a graduated scale. Combined with a multi-jointed cantilever design, loading and unloading battery packs becomes exceptionally easy. Technicians can operate the effortless joystick single-handedly, easily adjusting the massive battery pack to any comfortable maintenance angle.
- Single-person operation, freeing up manpower: Completely replaces the multiple workers required by traditional methods. One technician can independently complete the entire process from clamping, flipping, locking,and maintenance, directly freeing up valuable human resources.
- Integrated work station, seamless process: After the battery pack is securely fixed on the flipping frame, it can be used as a stable workbench. Maintenance personnel can continuously complete multiple processes,such as disassembly, inspection, maintenance, and testing on the flipping frame without repeated hoisting and relocation, making the maintenance process seamless and improving overall work efficiency by an estimated 30%-50%.
Value throughout the entire maintenance process
From battery pack offline to maintenance completion, the value of the Guheng Energy flipping frame is consistent:
- Disassembly and inspection stage: Easily flip to bottom-up, quickly complete the removal of lower shell bolts,and perform a comprehensive leakage and damage inspection.
- Internal Repair Stage: The battery pack can be tilted to provide optimal viewing angle and operating space for module hoisting, cell replacement, or electrical connection repairs.
- Welding and Sealing Stage: Locked at a precise angle, it provides an extremely stable platform for enclosure repair welding,and sealant application.
- Final Assembly and Testing Stage: Facilitates the installation of various pipes and wiring harnesses, and allows for rotation to a suitable position for final airtightness testing.
Investing in Professional Tools is Investing in Safety and the Future
In today’s rapidly developing new energy vehicle aftermarket, specialization, standardization, and tool-based approach to repair services are irreversible trends. For power battery pack repair, safety is the bottom line, and efficiency is the competitive advantage. Choosing professional equipment like the Guheng Energy battery pack tilting frame is far more than just a cost expenditure; it’s a primary guarantee for the safety of operators, a powerful protection of repair quality and customer assets, and a strategic investment for repair companies to improve efficiency and establish a professional brand image.
To do a good job, one must first have the right tools. Let professional tools mitigate high-risk operations, allowing technicians to focus their abilities on value creation. Guheng Energy is committed to providing innovative technological solutions and reliable battery pack repair equipment to help every industry partner safely and efficiently win every “turnaround battle,” jointly propelling the new energy vehicle repair industry toward a safer and more professional future.
FAQ
Q: Can your flipping rack truly adapt to different brands and shapes of battery packs?
A: Absolutely. Our battery pack flipping rack achieves broad compatibility through a multi-degree-of-freedom adjustable cantilever and clamping system. The clamping width and clamping height can be flexibly adjusted within the design range, and with various sizes of adapter pads, it can safely and securely clamp most power battery packs, from compact cars to large SUVs. Specific compatibility can be confirmed based on your commonly used battery pack models.
Q: How do you ensure the battery pack won’t suddenly slip or fall during the rotation of the flipping rack?
A: This is achieved through dual protection. First, the anti-slip pads on the inside of the clamps provide tremendous friction. Second, and most importantly, is our multi-level locking pin design. On the rotating shaft, a robust locking hole is provided at regular intervals (e.g., 15° or 30°). When the target angle is reached, inserting the pin into the hole achieves a rigid mechanical lock, ensuring the platform remains absolutely fixed and safe even when all power is disconnected.
Q: Is this equipment too “heavy” and expensive for small and medium-sized repair shops?
A: On the contrary, for small and medium-sized shops with continuously growing businesses, this is a crucial investment to improve capacity and safety. The direct losses and indirect impacts of a single battery pack drop accident can far exceed the price of the equipment. Our tilting frame helps you handle your core repair business safely and efficiently with minimal manpower (1 person), reducing vehicle time in the shop, taking on more orders, quickly recovering costs, and continuously generating profits. We offer models with different configurations, allowing you to choose the most economical one based on your business scale.
Q: Does the equipment require an external power supply? Is the operation complicated?
A: Our standard mobile tilting frame uses a purely mechanical, hydraulic, and manual operation design, requiring no external power supply. Simply insert the pin to lock. The mobile design is ideal for flexible use in the workshop. The user interface is simple and intuitive, and most people can safely operate it after a short training session. We also offer an optional electrically assisted rotation system to meet the needs of more frequent use.
