Lead-acid battery leakage verification method based on real vehicle

Abstract

The present invention relates to the technical field of automotive component quality verification and certification, disclosing a lead-acid battery leakage verification method based on a real vehicle. The method comprises the following steps: loading the lead-acid battery to be tested onto the vehicle, attaching pH test paper above the vent, consuming electricity, starting the vehicle with an external power supply, connecting the vehicle to an HDS diagnostic instrument, conducting a test run, and checking the pH test paper for discoloration. This method, based on a real vehicle, verifies the lead-acid battery's leakage resistance in the actual vehicle operating environment, providing greater authenticity.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile parts quality inspection and verification, and in particular to a lead-acid battery leakage inspection and verification method based on an actual vehicle. Background Art

[0002] Although batteries are tested for leakage resistance during the development stage, there are still many complaints of battery leakage in the market every year.

[0003] Battery leakage can be divided into two categories according to the leakage location:

[0004] 1. The electrolyte leaks from the sealing part;

[0005] 2. The electrolyte leaks from the battery vent, which is the most common cause of market complaints.

[0006] Although battery leakage may not seem to be a big problem, it can cause vehicle fire if it becomes serious.

[0007] In lead-acid battery manufacturing plants, gas testing is usually used to test the sealing of battery casings. During the development stage of lead-acid batteries, vibration testing is used to verify whether the battery is leaking. This is called a durability vibration test: at a high temperature (e.g. 75±3°C), the battery is charged and vibrated for a period of time (e.g. 2 hours) at a set vibration frequency, acceleration, and amplitude. The test is then made based on whether there is electrolyte leakage. This method is based on bench testing. Although it simulates the charging / discharging and vibration driving conditions of the entire vehicle battery, the actual vehicle operating conditions are complex, and the charging / discharging characteristics are affected by complex factors such as electrical equipment, load, energy consumption, and external environment, making it impossible to simulate them using experimental conditions. Summary of the Invention

[0008] The purpose of the present invention is to address the deficiencies of the above-mentioned technology and provide a lead-acid battery leakage verification method based on a real vehicle, which verifies the leakage prevention ability of the lead-acid battery in the actual vehicle usage environment and is more authentic.

[0009] To achieve the above-mentioned purpose, the present invention provides a lead-acid battery leakage verification method based on a real vehicle, comprising the following steps:

[0010] A) Load the lead-acid batteries to be tested into the vehicle according to the loading standards;

[0011] B) attaching pH test paper above the vent of the lead-acid battery to be tested;

[0012] C) turning on electrical devices in the vehicle to consume the power of the lead-acid battery to be tested, reducing the SOC of the lead-acid battery to less than 25%, and monitoring the power level with a battery meter. This utilizes the fact that the battery charge and discharge chemical reactions are more intense at low SOC, which is also in line with the common situation in the domestic market where the battery power is low and an external power supply is required for starting;

[0013] D) starting the vehicle with an external power supply, connecting the vehicle diagnostic device (HDS), and monitoring the charge / discharge current of the lead-acid battery to be tested;

[0014] E) Drive the vehicle onto the test track, first on the expressway, then into the rough road area and drive on the bumpy road, monitoring it in real time with the HDS diagnostic instrument;

[0015] F) When the HDS diagnostic instrument monitors that the charge / discharge current of the lead-acid battery to be tested fluctuates around 0A, the driver drives off the test track and checks whether the pH test paper on the lead-acid battery to be tested has changed color. If so, it means that electrolyte has leaked, and the lead-acid battery to be tested fails the leakage test. Otherwise, the test passes.

[0016] Preferably, in step B), the pH test paper is pasted above the exhaust hole of the lead-acid battery to be tested in an arch bridge shape to facilitate normal exhaust of the lead-acid battery to be tested.

[0017] Preferably, if the pH test paper on the lead-acid battery to be tested does not change color, repeat steps C) to F) 4 to 5 times. If the pH test paper on the lead-acid battery to be tested still does not change color, the lead-acid battery to be tested passes the test.

[0018] Preferably, in step E), the driving time on the expressway is 4 to 6 minutes, the vehicle speed is 70 to 90 km / h, and the vehicle speed on the bumpy road section is 25 to 35 km / h.

[0019] Compared with the prior art, the present invention has the following advantages:

[0020] 1. From test bench verification to actual vehicle verification, verifying the leakage prevention ability of lead-acid batteries in the actual vehicle usage environment is more authentic;

[0021] 2. Batteries that are proven to be leak-free on the test bench may still leak when tested on the actual vehicle and may also have batch defect characteristics;

[0022] 3. Incorporating the on-vehicle inspection and verification of battery leakage into the new model development and verification stage will help to detect battery leakage defects at an early stage, remedy them in time, and prevent them from entering the market;

[0023] 4. Improved the anti-overflow inspection and verification system for automotive lead-acid batteries. DETAILED DESCRIPTION

[0024] The present invention will be further described in detail below with reference to specific embodiments.

[0025] (1) Inspection and testing site:

[0026] Dongfeng Honda's third factory test track.

[0027] (2) Test tools:

[0028] Lead-acid battery to be tested, wrench (for disassembling and installing the lead-acid battery to be tested), battery tester (for measuring battery charge), HDS diagnostic instrument (for monitoring battery charge and discharge current), pH test paper (sticked to the exhaust port to determine whether there is leakage), external power supply (for starting the vehicle when the lead-acid battery to be tested is low on charge).

[0029] (3) Data measurement preparation

[0030] ①Battery performance measurement (battery measuring instrument)

[0031] ② Monitoring of current, voltage, internal resistance, etc. during battery charging and discharging (HDS)

[0032] This strategy was developed based on market complaints about battery leakage and the fact that lead-acid batteries experience more intense charge and discharge reactions at low SOC. It's common for vehicles to fail to start due to low battery charge, caused by prolonged parking or when the engine is turned off with electrical appliances still connected. Therefore, this operating condition isn't considered extreme. Statistics show that the remaining battery charge at this point is typically less than 50%. In this embodiment, the remaining charge is set at 20%, which allows the battery to return to normal after recharging.

[0033] The specific verification steps include:

[0034] A) Load the lead-acid batteries to be tested into the vehicle according to the loading standards;

[0035] B) Paste pH test paper above the vent of the lead-acid battery to be tested. The pH test paper should be pasted above the vent of the lead-acid battery to be tested in the shape of an arch bridge.

[0036] C) Turn on the electrical devices in the vehicle to consume the power of the lead-acid battery to be tested, so that the SOC of the lead-acid battery to be tested is 20%;

[0037] D) Start the vehicle with an external power source, without turning on other electrical devices in the vehicle, and connect the HDS diagnostic instrument to monitor the charge / discharge current of the lead-acid battery to be tested;

[0038] E) Drive the vehicle onto a test track and drive on an expressway for 5 minutes at a speed of 80 km / h. Driving on the expressway allows the vehicle's generator to charge the lead-acid battery under test with a high current. During this time, a vigorous chemical reaction occurs within the battery, generating a large number of bubbles on the plate surfaces and causing a rapid temperature rise. The vehicle then enters a rough road area and drives on bumpy sections at a speed of 25-35 km / h, monitored in real time by an HDS diagnostic instrument. Bubbles (hydrogen and oxygen) generated by the chemical reaction on the battery plates initially adhere to the plates, causing the electrolyte level to rise. When the bubbles burst, gas will escape from the vents. If the electrolyte level rises too high, coupled with the vehicle's shaking on the bumpy road, battery leakage may occur.

[0039] F) When the HDS diagnostic instrument monitors that the charge and discharge current of the lead-acid battery to be tested is 0, the lead-acid battery to be tested is now fully charged. Drive off the test track and check whether the pH test paper on the lead-acid battery to be tested has changed color. If it has changed color, it means that electrolyte has leaked out, and the lead-acid battery to be tested has failed the leakage test. Otherwise, repeat steps C) to F) 4 to 5 times. If the pH test paper on the lead-acid battery to be tested still does not change color, the lead-acid battery to be tested has passed the test.

[0040] In the present invention, when electrolyte leakage occurs, it can be clearly detected by utilizing the property of pH test paper that turns red when encountering acid.

[0041] The present invention is based on a lead-acid battery leakage verification method for a real vehicle. From test bench verification to real vehicle verification, the leakage prevention capability of the lead-acid battery is verified in the actual vehicle use environment, which is more authentic. A battery that is verified to be leak-free on a test bench may still leak when verified on a real vehicle, which may be a batch problem. Incorporating real vehicle verification of battery leakage into the new model development and verification stage is conducive to early discovery of battery leakage defects, timely remediation, and prevention of battery leakage from entering the market. The anti-overflow verification system for automotive lead-acid batteries is improved.

Claims

1. A lead-acid battery leakage verification method based on a real vehicle, characterized by: The steps include: A) Load the lead-acid batteries to be tested into the vehicle according to the loading standards; B) attaching a pH test paper above the exhaust hole of the lead-acid battery to be tested, wherein the pH test paper is attached above the exhaust hole of the lead-acid battery to be tested in an arch bridge shape; C) turning on electrical devices in the vehicle to consume the power of the lead-acid battery to be tested, so that the SOC of the lead-acid battery to be tested is less than 25%; D) Start the vehicle with an external power supply, connect the HDS diagnostic instrument, and monitor the charge and discharge current of the lead-acid battery to be tested; E) Drive the vehicle onto the test track, first on the expressway, then into the rough road area and drive on the bumpy road. Monitor the vehicle in real time using the HDS diagnostic instrument. The driving time on the expressway is 4-6 minutes at a speed of 70-90 km / h, and the speed on the bumpy road is 25-35 km / h. F) When the HDS diagnostic instrument monitors that the charge and discharge current of the lead-acid battery to be tested is 0, the driver drives off the test track and checks whether the pH test paper on the lead-acid battery to be tested has changed color. If it has changed color, it means that electrolyte has leaked, and the lead-acid battery to be tested has failed the leakage test. Otherwise, the test has passed.

2. The lead-acid battery leakage verification method based on a real vehicle as claimed in claim 1, characterized in that: If the pH test paper on the lead-acid battery to be tested does not change color, repeat steps C) to F) 4 to 5 times. If the pH test paper on the lead-acid battery to be tested still does not change color, the lead-acid battery to be tested passes the test.