From power battery packs to onboard sensors, sealing performance is the first line of defense for waterproofing, dust protection, and insulation stability in new energy vehicle high-voltage components. This article outlines the sealing test requirements, industry standards, and inspection solutions for 8 core new energy components, helping engineers quickly complete model selection and production line planning.
Against the backdrop of the rapid growth of the new energy vehicle industry, the safety and reliability of the three-electric system has become a core criterion for evaluating overall vehicle quality. From power battery packs to onboard sensors, every critical component must undergo precise air tightness sealing tests to meet IP rating and full lifecycle reliability requirements.
The following are the mainstream core components of new energy vehicles that require sealing tests, along with their corresponding test parameters and PLUS intelligent adaptation solutions, covering core scenarios such as the three-electric system, thermal management, and body electronics.
Test pressure:Positive pressure 2-5kPa (negative pressure customizable)
Leak standard:IP67 corresponds to ≤10-30mL/min, while high-end vehicle models have an internal control standard of ≤5mL/min.
According to the standard:GB 38031-2020、ISO 20653
Compatible with PLUS smart solutions:
Test pressure:30-100kPa
Leak standard:IP67 rating ≤5cm³/min
According to the standard:GB/T 18488.1-2015
Compatible with PLUS smart solutions:
Test pressure:30-80kPa
Leak standard:IP67 rating ≤0.5mL/min
Compatible with PLUS smart solutions:
Test pressure:200-400kPa (high-pressure condition)
Leak standard:Dry test method ≤2.5 mL/min
According to the standard:QC/T 1206.2-2024
Compatible with PLUS smart solutions:
Test pressure:50-200kPa
Leak standard:≤0.3 mL/min, meeting high-voltage insulation protection requirements
Compatible with PLUS smart solutions:
Test pressure:≥200kPa
Leak standard:≤1 mL/min, no visible leakage
According to the standard:GB/T 18488.1-2015
Compatible with PLUS smart solutions:
Test pressure:10-30kPa
Leak standard:IP67 rating ≤0.5mL/min, anti-fogging and waterproof
Compatible with PLUS smart solutions:
Test pressure:10-20kPa
Leak standard:IP67/IP69K rating ≤0.5mL/min
Compatible with PLUS smart solutions:
Compared with traditional fuel vehicles, new energy vehicles face more stringent technical requirements for sealing tests, primarily due to three key industry characteristics:
The operating voltage of the three-electric system (battery, motor, and electronic control) generally reaches above 300V, with some high-voltage platforms exceeding 800V. Once moisture intrudes into the housing, it will directly cause short circuits, insulation failure, or even thermal runaway, thus imposing zero-tolerance requirements on sealing reliability.
New energy vehicles must withstand complex operating conditions such as extreme temperature cycling from -40°C to 85°C, high-speed water wading, and high-pressure washing. Their sealing structures must endure the long-term effects of thermal stress and water pressure impact, and static IP certification alone cannot cover real-world usage scenarios.
The industry generally requires power batteries and electric drive systems to meet an 8-year/150,000-kilometer warranty, with sealing performance remaining stable throughout the entire lifecycle, which sets higher standards for testing accuracy and aging verification.
For high-volume end-of-line testing of small and medium-sized components, the PLUS four-station sealing test equipment can achieve4 workpieces tested simultaneously, the fastest single-cycle takt time can reach10 seconds/piece, significantly improving production line inspection efficiency while ensuring a detection accuracy of ±1Pa, perfectly suited to the batch inspection needs of components such as controllers, connectors, vehicle lights, and sensors.
From micro-leak detection with precision sensors, to large-volume sealing tests for power battery packs, and to high-pressure leak detection for liquid cooling systems, PLUS intelligent equipment covers1Pa to 10MPa full pressure range, supporting multiple testing methods such as differential pressure, direct pressure, flow, and helium mass spectrometry, with optimal testing solutions customized to the characteristics of each component.
In response to the irregular shapes and multiple ports of new energy components, we can customize profile-matched sealing fixtures and quick-connect fixtures. We also support deep integration with robotic arms, production lines, and MES systems to achieve full-process automation covering loading, testing, judgment, and data upload, meeting the needs of unmanned production lines.
The equipment comes with a built-in test data storage function, supporting full recording of workpiece ID, leak value, test time and other information. It can be integrated with the enterprise quality management system to meet the traceability requirements of IATF 16949 and other automotive industry system certifications, helping customers achieve closed-loop quality management.
PLUS Intelligent has provided sealing test equipment and customized solutions to dozens of domestic new energy vehicle manufacturers and Tier 1 component suppliers, covering the entire industry chain including power batteries, electric drive systems, thermal management, and body electronics. The equipment's stability and testing accuracy have been widely recognized by customers.
| Application Scenarios | Recommended Solution | Compatible parts |
|---|---|---|
| R&D Laboratory | High-precision helium mass spectrometer leak detection equipment | Leak point location, material sealing verification, standard benchmarking test |
| Component mass production line | Four-station/multi-station air tightness testing equipment | Controllers, OBCs, vehicle lights, connectors, and other small-to-medium components for batch testing |
| Battery PACK production line | Large-volume dedicated air tightness test system | Pack-level sealing test, compatible with battery packs of different capacities |
| End-of-Line (EOL) Vehicle Testing | Complete Vehicle-Level Sealing Test Solution | Vehicle-level waterproof verification for charging ports, vehicle cabins, and other vehicle-level components |
If you have specific sealing test requirements for components, please provide the workpiece parameters, test pressure, and leak criteria, and PLUS Intelligent will customize the equipment selection and test solution for you.
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