What are the causes of electric vehicle insulation failure?
4 Answers
Electric vehicle insulation failure occurs due to the following reasons: 1. Cause: Insulation failure is caused by leakage of the electrolyte inside the battery, leading to liquid seepage. When the liquid seeps to a certain extent, the insulation layer is damaged, creating a conductive circuit between the battery modules and cells, which triggers the fault warning. If only one point of insulation fails in the system, it may not have an immediate significant impact, but multiple points of insulation failure can cause leakage current to flow between these points, potentially leading to a fire. 2. Solution: Handling insulation failure is complex. Operators must wear protective equipment that meets national safety standards, such as insulated gloves and insulated shoes. When insulation failure occurs, the faulty battery pack usually needs to be replaced. In cases of multiple insulation failures, the entire battery may need to be replaced.
I've run an auto repair shop for over a decade and handled numerous cases of electric vehicle insulation failures. The most common issue is aging and cracking of insulation materials, especially in high-voltage cable sections, which deteriorate over time due to weather exposure, leading to leakage or short circuits. Moisture intrusion is another culprit – for instance, when vehicles don't dry thoroughly after driving through water during rainy seasons, causing damp wires to degrade insulation performance. Post-accident neglect in repairs can also create hazards. When the insulation warning light comes on, immediately stop and inspect to avoid electric shock risks. My advice: conduct regular comprehensive checks on battery packs and wiring, store vehicles in dry environments, and seek professional repair at any sign of abnormality – never attempt DIY fixes to prevent dangers. Safety comes first; though this fault is common, improper handling can lead to severe consequences.
I bought a new electric car last year and it's been a blast to drive, but last month I got a sudden insulation alarm that gave me a scare. The reason? Probably the wiring got worn out from highway driving, or maybe water got in after heavy rain due to poor door sealing, causing a short circuit. After inspection, it turned out to be insulation failure caused by aging and wear. Now, I regularly check the chassis and battery area for any abnormalities and avoid parking in puddles. I recommend everyone to pay attention to dashboard warning lights and not delay in addressing issues—contacting the manufacturer's after-sales service is quick and reliable. Regular maintenance can reduce such faults, ensuring a safe and comfortable drive. Electric cars are eco-friendly, but they require careful handling.
As a tech enthusiast, I've found that the key to electric vehicle insulation faults lies in the breakdown of the high-voltage system's protective layer causing leakage. There are two main reasons: first, material degradation and aging, where high temperatures or vibrations can make the insulation layer brittle and crack; second, environmental factors, such as moisture infiltration in humid areas leading to short circuits. Design flaws can also create hidden risks. To prevent this, regularly update the software to monitor system status and choose dry parking spots. Any issues in the high-voltage part will trigger an alarm, and severe cases may damage the battery, so prompt diagnosis and repair are essential—simple checks can prevent major troubles.
