The rapid rise of Electric Vehicles (EVs) has brought a critical safety challenge to the forefront: thermal runaway. One of the primary causes of battery failure is the ingress of moisture or the leakage of coolant.
To prevent catastrophic failures, the automotive industry has set stringent standards (IP67/IP68). Traditional testing methods are no longer sufficient. Here is why EV battery leak testing relies heavily on helium tracer gas.
1. The Challenge of “Micro-Channels”
Water molecules are small, but moisture intrusion can occur through microscopic cracks in welds or seals that are invisible to the naked eye.
- Battery Packs: Large trays with long sealing perimeters are prone to micro-leaks.
- Liquid Cooling Plates: These components circulate coolant directly next to battery cells. Even a microscopic coolant leak can cause a short circuit.
2. The Solution: Vacuum Chamber Helium Testing
For EV components, the vacuum chamber method is the gold standard.
The part (e.g., a battery pack) is placed in a chamber, air is evacuated, and the part is pressurized with helium. If there is a leak, helium escapes into the vacuum chamber and is instantly detected by a mass spectrometer.
- حساسية عالية: Detects leaks down to $1 \times 10^{-6}$ mbar·l/s (standard for battery packs).
- Global Compliance: Meets strict OEM standards and UN 38.3 transport regulations.
3. Managing Production Cycle Times
EV manufacturing is fast-paced. Our أنظمة كشف تسرب الهيليوم are engineered for speed. By using multi-chamber designs and optimized vacuum cycles, we ensure that rigorous testing does not become a bottleneck on your assembly line.
خاتمة
Safety is non-negotiable in the EV market. Using advanced helium detection ensures that every battery pack leaving your factory is sealed, safe, and road-ready.
[> Check our EV Battery Leak Testing Solution Here.]
FAQ: Helium Testing for EV Components
Q1: What standards are used for testing EV battery pack tightness?
A: Most automotive OEMs require battery packs to meet strict IP67 or IP68 waterproof ratings to prevent moisture ingress. These high standards demand the detection of extremely microscopic leak paths.
Q2: Can this equipment test cooling plates (liquid cooling systems)?
A: Yes. Cooling plates require even higher sensitivity to prevent coolant from leaking onto cells. Helium testing is the preferred method for these components.
Q3: Is this testing destructive?
A: No. Helium leak detection is a Non-Destructive Testing (NDT) method. The part remains clean, dry, and undamaged after the test, ready for the next assembly step.