From 5 Million Yuan in Recall Losses to Zero Failures! Helium leak detection equipment saves automakers 1.2 Million Yuan in annual production capacity costs!
In the new energy vehicle industry, the sealing of battery packs directly determines vehicle safety and user trust. Once a microleak occurs, coolant seeps into the battery cells, potentially causing a short circuit and fire. However, traditional hydrostatic testing or bubble testing methods have trapped countless automakers in a "cost trap."
A leading new energy vehicle company revealed that using the traditional bubble testing method for battery packs requires repeated manual immersion and observation, takes up to 40 minutes per test, and can only process a maximum of 200 battery packs per day per production line. Furthermore, traditional methods cannot accurately locate microleak points (leak rates below 1×10⁻⁵ Pa・m³/s are difficult to detect), resulting in approximately 3% of "invisible defective products" flowing downstream. These battery packs malfunctioned after one to two years of use, forcing the company to bear hefty recall costs. Logistics and repair fees alone for a single recall exceeded 5 million yuan, and the company also lost orders due to damaged reputation.
The introduction of helium leak detection equipment completely reversed this situation. Helium, an inert gas with a molecular diameter of just 0.26nm, can accurately detect micro-leaks that traditional methods miss. Furthermore, the automated testing process reduced the inspection time per unit to 8 minutes, increasing the production line's daily capacity to 800 units, eliminating the need for two temporary production lines and saving over 1.2 million yuan in annual labor and equipment costs. More importantly, the micro-leak detection rate increased to 99.9%. In the past three years, the company has had zero battery pack recalls, avoiding recall losses in the tens of millions of yuan.
However, cost reductions in the new energy vehicle industry are just the tip of the iceberg for helium leak detection equipment. In the field of electronic components requiring high-precision sealing, the "hidden waste" caused by traditional leak detection methods is even more alarming. In the next article, we will reveal how helium leak detection equipment helps electronic component companies eliminate over 800,000 yuan in material loss each year.
