In today's rapidly developing new energy energy storage industry, energy storage batteries, as the core energy storage units, have reliability that directly determines the safety and efficiency of the entire energy storage system. The sealing performance of the terminal posts is a key core indicator affecting the service life, safety and stability of the battery. Once the terminal post seal fails, it can easily cause serious problems such as liquid leakage, corrosion, bulging, and even fire, bringing huge economic losses and safety risks to enterprises. To this end, we have independently developed the "Energy Storage Battery Terminal Post Sealing Performance Testing Device," supported by scientific and efficient testing methods and processes, providing a comprehensive solution for energy storage battery quality control.
Traditional terminal sealing inspection methods mostly rely on manual visual inspection, immersion observation and other rough means, which are not only inefficient but also unable to accurately capture tiny leak hazards, resulting in extremely high rates of missed and false detections and making it difficult to meet the quality control requirements of large-scale industrial production. Our testing equipment, with the core advantages of "precise sensing, intelligent judgment, and high efficiency and convenience," completely solves these industry pain points.
This device adopts multi-dimensional sensor fusion technology and is equipped with high-precision pressure sensors and micro-flow monitoring modules. It can perform dynamic pressure testing and precisely capture leakage on pole sealing areas, detecting pressure changes as small as 0.01MPa, with leakage detection sensitivity reaching 0.1mL/h, far exceeding conventional industry standards. The device is equipped with an adaptive fixture system that is compatible with energy storage batteries of different specifications and pole types from 12V to 1500V, eliminating the need for frequent fixture changes and greatly improving testing versatility. In addition, the device integrates an intelligent control system, enabling visualized operation through a 7-inch touchscreen display. It supports parameter presetting, real-time data acquisition, and dynamic curve display. Test results are automatically judged and standardized reports are generated. It can connect directly to enterprise MES systems to enable traceability and digital management of testing data.
To match the advanced testing equipment, we have established a complete and rigorous set of testing methods and procedures to ensure the scientific validity and authority of the test results. The testing process is mainly divided into four core stages:
The first stage is sample pre-treatment. Operators need to clean the surface of the battery to be tested, removing oil, dust and other impurities from the terminal posts to ensure there are no interfering factors on the sealing surface. Then, the adaptive fixture of the device should be adjusted according to the battery model to secure the battery precisely, ensuring a seamless fit between the terminal posts and the sealing chamber of the testing device, and avoiding any impact on test results caused by installation deviation.
The second stage is the sealing performance test. After the device is started, the system automatically injects an inert gas (such as nitrogen) into the terminal sealing cavity according to preset parameters, creating a stable test pressure environment within the cavity. The pressure range can be freely adjusted between 0.1 and 1.0 MPa according to battery specifications to meet the testing requirements of different scenarios. During the pressure holding process, high-precision sensors collect pressure data and gas flow changes in real time, and the intelligent system analyzes the data through algorithms to determine whether leakage exists and its severity level. The entire testing process takes only 3-5 minutes, improving efficiency by more than 80% compared with traditional methods.
The third stage is result determination and recording. After the test is completed, the system automatically generates a "Pass/Fail" determination result and simultaneously outputs detailed test data, including hold time, pressure change curve, leak rate values, and other information. All data supports both local storage and cloud upload, ensuring the integrity and traceability of test records and providing reliable data support for enterprise quality analysis.
The fourth stage is exception handling and feedback. For products that fail the test, the system can automatically mark them and trigger an alarm. Based on the test data, staff can locate the leak position and identify the cause, providing precise guidance for production process optimization and helping enterprises reduce the defect rate at the source.
This testing device and its supporting method have passed the authoritative certification of the National New Energy Testing Center. It is widely applicable to scenarios such as factory inspection by energy storage battery manufacturers, incoming inspection by energy storage system integrators, and periodic sampling inspection by operation and maintenance companies. It has now established partnerships with a number of leading energy storage enterprises. After being put into use, it has helped enterprises reduce the terminal sealing defect rate from the original 3.2% to 0.15%, cutting annual losses caused by sealing issues by more than ten million yuan, and has been highly recognized by industry customers.
Driven by the "dual carbon" goals, the energy storage industry is experiencing explosive growth, and battery quality and safety have become the lifeline of industry development. Our sealing performance testing equipment for energy storage battery terminals takes technological innovation as its core and precision and efficiency as its goal, building a solid quality defense line for energy storage enterprises.
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