Application of air tightness detector in new energy vehicle industry

The main components of electric vehicle are composed of three parts: motor, battery and electric control. General consumers will be worried that leakage of electricity and short circuits will occur when high voltage parts of electric vehicles such as batteries and motors are flooded. The car engineer will of course consider the problem. The protection level of many electric vehicles has reached the level of IP67 (IP (Ingress ProtectionRating) for protection safety level. The first number after IP is dustproof grade, and the second numbers are waterproof grade).

As a strong development industry in China in recent years, new energy vehicles have sprang up many automobile and spare parts manufacturers. The "13th Five-Year" plan outline proposed, implemented the new energy vehicle extension plan, vigorously developed the pure electric vehicle and the plug in hybrid electric vehicle, and emphasized the energy density and the height of the power battery. The key technologies of temperature adaptability and so on, the total sales volume of new energy vehicles nationwide has reached 5 million vehicles.

The new energy vehicles are different from the previous fuel power, and are driven by the hydrogen power and power battery. The safety requirements of the components are higher, and more components have higher requirements for the air tightness. Far intelligence technology has been used in a large number of new energy components, such as variable speed motor, power battery, vehicle controller, DC converter and other new energy components. Mature technology and reliable product detection ability help to improve the quality of customers.

Yuan Zhi company provides some testing methods for the detection of parts of new energy vehicles, and provides reference for various manufacturers.

I. air tightness test of new energy vehicle motor channel

The automobile transmission of new energy uses variable speed motor, and the shell of the motor has a cooling water channel. In order to ensure the complete seal of the waterway, the water does not leak and damage the electrical parts of the motor. Many manufacturers have adopted the A850 type gas tightness tester produced by far intelligence technology, the test pressure of the motor shell waterway is 2. 50kPa (or 2.5bar), water leakage is 5 minutes without leakage, the interest gas tightness detector detection index is 250kPa, inflatable 20S, balance 40S, leakage value less than 3Pa/s to be qualified.

Two. Gas tightness detection of power battery

The battery is filled with batteries, and there are a large number of electrical components and batteries, which are damaged to prevent the battery from receiving rain or water.

Many manufacturers use the IP65 waterproof testing standards, but can not be put into water testing. The best alternative is to use the ZA200 super low pressure large volume gas tightness tester produced by the company of far intelligence company. The instrument uses electronic pulse aeration, and can quickly fill up the gas in the PACK battery box of tens to several hundred liters without breaking. The bad battery box itself. The function and effect of quick detection are achieved, and the detection efficiency is greatly improved.

Test index: the test pressure is between 2000Pa-10000Pa, the volume of the ordinary passenger car and the bus car battery box is different, the pressure has some changes, the inflating time is about 60S, the balance is about 30S, the leakage value is about 2-3Pa/s (or 30S is not greater than 80Pa).

Three. Detection of DC converter and charging system of new energy vehicles

In an electric vehicle with fuel cell as the power source, a DC/DC converter is needed to be added between the fuel cell and the inverter because of the soft output characteristics of the fuel cell and the instability of the output voltage. The DC/DC converter plays the following role in the fuel cell electric vehicle: (I) voltage conversion: the output voltage of the fuel cell is transformed by the DC/DC converter and then supplied to the motor driver. (2) stable voltage: the output voltage of fuel cell is unstable, and it is regulated by DC/DC converter closed loop control system.

Similarly, the DC converter has the requirement of waterproof grade and must meet the requirements of IP65. The remote sensing company uses ZA200 type gas tight detector to achieve this kind of testing.

The inflatable pressure is 10-30kPa. The electronic pulse is fast, the volume of 10L is charged, the 15S is charged, the 20S is balanced, the 10S is detected, and the leakage rate is controlled within 50Pa. It is connected by the quick thread connector produced by far wise company.

Four. Air tightness detection of vehicle controller VCU

The VCU (Vehicle Control Unit) is the core component of the electric vehicle control system. It is the core control device for controlling the starting, running, moving, speed, stopping, and other electronic devices of the electric motor. As the core component of pure electric vehicle control system, VCU takes the task of data exchange, security management, driver's intention interpretation and energy flow management.

The product has a clear need to meet the waterproof requirements of IP67, using the A810 leak detector of far intelligence company to test, test the pressure level 10-20KPa, and control the leakage rate within the range of 5Pa/s.