With the continuous growth in the number of new energy vehicles, the demand for maintenance, testing, and secondary use of new energy vehicle power batteries is constantly increasing. During power battery maintenance, many companies focus on capacity decay, state of charge (SOC), and insulation performance, but often overlook a crucial aspect—air tightness testing. In fact, for new energy power battery packs, good sealing performance directly affects battery safety, lifespan, and overall vehicle reliability. Therefore, air tightness testers and battery pack charge/discharge testing equipment have become indispensable components of the power battery maintenance system.
What sealing risks do power batteries for new energy vehicles face?
New energy vehicle power batteries operate in complex environments such as high temperature, low temperature, vibration, and humidity for a long time, and the sealing structure inside the battery pack will gradually age over time.
Why are new energy power battery packs prone to sealing failure?
Common causes include:
The sealing ring has aged and deformed;
Long-term vibration of the battery box has caused structural loosening.
The sealing performance of the high-voltage connector deteriorates;
Explosion-proof valve and vent valve failed;
The seals were not properly installed after repair and disassembly.
Especially after module replacement, BMS repair, or battery pack opening and inspection, even with minimal assembly error, micro-leakage may occur in the new energy power battery pack.
What are the consequences of water vapor entering the battery pack of a new energy vehicle?
When the sealing performance deteriorates, moisture and dust in the air may enter the battery pack, causing:
Cell corrosion;
The insulation resistance decreased;
High-voltage system failure;
Battery capacity degradation is accelerating;
The risk of thermal runaway increases.
Therefore, the sealing performance of new energy vehicle power batteries must be confirmed through professional testing after maintenance.
Why has airtightness testing become a mandatory inspection item for the maintenance of power batteries?
The core objective of airtightness testing is to verify whether new energy power battery packs have the protective capabilities designed by the original manufacturer.
Most leaks are micro-leaks, with extremely small leakage amounts, making them difficult to detect using traditional soapy water testing or visual inspection.
Professional airtightness testing instruments can detect minute pressure changes through a high-precision pressure acquisition system, thereby quickly determining whether there is a risk of leakage . Battery repair involves: opening the casing; disassembling and assembling modules; replacing wiring harnesses; and maintaining high-voltage components; all of which affect the original sealing structure. Therefore, even after repair, it cannot be guaranteed that the new energy battery pack will be restored to its original factory sealing condition; it must be verified through testing.
How do airtightness testing instruments ensure the safety of new energy power battery packs?
What is a professional airtightness tester?
Guheng Energy ‘s QMM series airtightness testers are primarily used for testing high-protection-level components such as power battery packs, liquid cooling plates, PDUs, and PEUs. The equipment employs automatic pressure stabilization control technology and high-precision pressure sampling technology, enabling automatic adjustment, rapid balancing, and high-precision testing of the test pressure.
What are the core advantages of an airtightness tester?
Compared to traditional testing methods, specialized equipment has the following advantages:
High detection accuracy;
Automatically generate test reports;
Supports QR code scanning for document creation;
Supports integration with MES systems;
Data traceability management;
Supports batch testing jobs.
For new energy vehicle power battery maintenance companies, this not only improves testing efficiency but also enables the establishment of a standardized quality management system.
conclusion
Against the backdrop of the rapid development of new energy vehicles, power battery maintenance is gradually upgrading towards standardization and digitalization. For new energy vehicle power batteries, sealing performance is a crucial factor affecting safe operation. Whether it’s module replacement, open-cover repair, or accident vehicle repair, new energy power battery packs must undergo airtightness testing.
Professional airtightness testing equipment can effectively detect hidden leakage risks; combined with battery pack charge/discharge testing equipment, it can comprehensively verify the battery’s health status and maintenance quality. Together, they form a closed loop for power battery maintenance quality.
As a provider of new energy service technology solutions, Guheng Energy has long focused on the field of power battery testing and maintenance, and has developed a series of products such as airtightness testing, final inspection testing, and battery pack charging and discharging maintenance , which are widely used in the fields of new energy vehicle after-sales service, manufacturing and energy storage.
For maintenance companies, establishing a comprehensive airtightness testing and performance testing system can not only improve the quality of maintenance, but also serve as an important foundation for ensuring the safe operation of power batteries in new energy vehicles.
FAQ
Q: Why is it necessary to conduct an airtightness test after repairing the power battery of a new energy vehicle?
A: Because maintenance and disassembly can affect the original sealing structure, and minute leaks are difficult to detect with the naked eye. Using an airtightness tester can quickly verify whether the new energy power battery pack meets the requirements for waterproofing, dustproofing, and safety.
Q: In which scenarios is the airtightness tester from Guheng Energy suitable?
A: Applicable to production testing and after-sales maintenance testing of power batteries, energy storage battery systems, liquid cooling plates and high-voltage components for new energy vehicles.
Q: How often should a new energy power battery pack undergo an airtightness test?
A: For any repair involving opening the cover, module replacement, water immersion repair, or major maintenance, it is recommended to re-perform the airtightness test to ensure that the battery pack’s sealing performance meets safety requirements.
