Routine maintenance is to check and eliminate potential safety hazards that affect the use of power batteries to avoid dangerous accidents. By formulating a regular preventive maintenance plan, you can better understand the health status and end-of-life of the electric vehicle batteries used, and determine the replacement or key maintenance plan for the batteries. Routine maintenance is generally performed once a month.
1. Maintenance procedures
① After the power battery system has been used for 1-2 months, the maintenance personnel need to maintain and maintain the appearance and insulation of the power battery system.
② After the power supply system has been used for 3 months, if conditions permit, the power supply system should be charged and discharged for maintenance.
③ Maintenance personnel must wear protective equipment such as insulating gloves when operating, and must be familiar with the structure, working principle and instruction manual of the power battery product before use.
④ When performing charging and discharging maintenance, connect the power battery system in place according to normal working requirements, turn on the power of the management system, monitor the status of the battery, and determine whether the ambient temperature, battery temperature and battery voltage of the battery are normal based on the monitored data.
⑤ Before performing charging and discharging maintenance, the operator should first check the conditions of each part of the power battery system, and only perform charging and discharging maintenance when ensuring that each part is normal.
⑥ Maintenance should be carried out in an environment with a temperature of 15-30℃; relative humidity: 45%-75%; atmospheric pressure: 86-106kPa.
⑦ During the charging and discharging maintenance process, check whether the management system functions normally.
⑧ During the charging and discharging maintenance process, check whether the fan is turned on and off at the specified temperature and whether it operates normally.
⑨ After the charging and discharging maintenance of the product, test the insulation resistance of the battery pack, and the measured insulation resistance should meet the index requirements. Use a voltmeter to test the positive terminal, negative terminal and maximum voltage of the battery pack, and the measured voltage value should not exceed the upper limit requirement.
⑩ If the functions of the electric vehicle power battery system are normal after maintenance, then use it again. If there are abnormal conditions and faults, they should be eliminated immediately. If the fault cannot be eliminated, contact the manufacturer in time.
2. Maintenance content
① Check the status of the power battery system.
② Check whether the management system functions normally.
③ Perform battery charging and discharging maintenance.
3.Maintenance method
3.1 Appearance maintenance
Check the appearance of the power system as follows. If there is any problem, it should be eliminated in time. If it cannot be eliminated, please contact the manufacturer in time.
① Check whether the battery pack box is intact and whether there is any damage or corrosion;
② Check whether the bolts and nuts of each fastener are loose;
③ Check whether the connecting wires between the battery packs are loose;
④ Check whether the plug is intact, whether the various wiring harnesses are damaged or scratched, and whether there are any exposed metal parts;
⑤ Check whether the cooling channel of the battery pack is abnormal.
3.2 Insulation
Disconnect the high-voltage connection between the battery pack and the whole vehicle, and use a digital voltmeter to measure the voltage of the total positive and total negative terminals of each battery pack to the vehicle body to see if it is less than the upper limit. If the voltage is found to be high, the insulation between the battery pack box and the vehicle body should be measured. If there is a problem, it should be repaired by a professional. Usually, it is possible to roughly determine which of the power systems composed of multiple battery packs has insulation problems with the vehicle body based on the system's total positive and total negative voltages to the vehicle body; by measuring the total positive and total negative voltages of the battery pack to the battery pack shell, the battery module with insulation failure in the battery pack can be roughly determined. If the insulation performance test is normal, then charge and discharge maintenance is performed.
3.3 Electric vehicle battery and management system
① Turn on the battery management system, collect and record the total voltage of the battery pack, the voltage of each battery module, and the temperature of each battery module in the open circuit state.
② Perform charge and discharge tests on the system according to the manufacturer's recommended charge and discharge system.
③ During the charge and discharge process, check whether the current, voltage, temperature and SOC displayed by the battery management system are correct; during the normal operation of the vehicle, check whether the management system data display is normal; otherwise, troubleshoot.
④ Turn on the auxiliary power supply, run the vehicle until the cooling system works, and observe whether the cooling channel is unobstructed.
⑤ Check whether the connection between the management system and each part is loose.
3.4 Cooling system
Check whether the inlet and outlet air channels are smooth and whether the fan can work normally. Remove dust and debris from the dust screen, or replace the dust screen.
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4. Precautions
① When the power supply system is in use, its positive and negative poles must be correctly identified, and it must not be connected in reverse or short-circuited.
② It is recommended to charge at an ambient temperature of 0-30℃.
③ When the power supply system is in use, the discharge termination voltage should be strictly controlled not to be lower than the minimum discharge voltage
④ The connections of the power supply system should be firm and reliable, and the power supply system should avoid working in an inverted state.
⑤ Avoid overcharging the power supply system for a long time.
⑥ Too high or too low ambient temperature will have an adverse effect on the charging efficiency, discharge capacity, voltage stability and service life of the power supply system.
⑦ If an abnormal situation occurs in the power supply system of an electric vehicle during use, the power supply should be disconnected immediately, and the manufacturer should be contacted for repair in time.
⑧ It is strictly forbidden to use metal or wires to contact the positive and negative poles of the power supply system at the same time to avoid short circuit. A fully charged power supply system should prevent short circuit, otherwise it will seriously damage the battery and even cause danger. During transportation and use, do not damage or disassemble the battery pack to avoid short circuit of the battery pack.
⑨The power supply system should be stored in a dry and ventilated environment with a temperature not higher than 35°C. Do not approach fire sources and avoid contact with acid or other corrosive gases.
⑩If there is any odor or abnormal sound during the charging and discharging process of the power supply system, please stop charging immediately.
Acey Intelligent specializes in providing one-stop solutions for semi-automatic/fully-automatic assembly lines of lithium battery packs used in ESS, UAV, E-Bike, E-Scooter, Power Tools, Two/Three Wheelers, Etc. In Addition, we provide a complete set of battery pack assembly equipment, such as Cell Grading Machine, Battery Sorting Machine, Insulation Paper Sticking Machine, CCD tester, Manual/Automatic Spot Welding Machine, BMS Tester, Battery Comprehensive Tester and Battery Pack Test System, etc.