What is the Solution for Insulation Fault in New Energy Vehicles?
3 Answers
Vehicles continuously perform insulation fault detection during normal operation; when an insulation fault occurs. Disconnect the positive and negative relays A of non-critical components, and recheck whether severe insulation faults still exist. Disconnect the positive and negative relays B of critical components, and recheck whether severe insulation faults still exist. If yes, proceed to the next step. Disconnect all high-voltage systems, stop driving, display severe insulation faults on the dashboard, and wait for rescue.
As an experienced mechanic, handling insulation faults in new energy vehicles requires a step-by-step approach. I usually start by using an insulation tester to measure the resistance of the high-voltage system. If the reading is abnormally low, it indicates a leakage point. Then, I focus on inspecting the battery pack, motor wiring, and connectors for any signs of damage or water ingress. Once the problem source is identified, the damaged insulation components, such as sealing rings or wire sleeves, must be replaced. High voltage is no joke—always power off the system before working and wear insulated gloves for safety. Prevention is also crucial. Avoid leaving the car wet for extended periods after washing, and conduct a comprehensive insulation test during regular maintenance to prevent major issues. With rapid advancements in new energy vehicle technology, some newer models come with built-in smart warning systems that automatically monitor insulation status, helping owners detect risks early.
Last year, my electric vehicle experienced an insulation failure, which gave me quite a scare. At that time, the dashboard alerted me about a risk of electric leakage, so I immediately stopped the car, turned off the engine, and cut the power, not daring to restart it. I called the 4S store for rescue, and after their inspection, they found that the sealing ring at the bottom of the battery pack had aged and allowed water to seep in. The repair took over a week, but fortunately, it was still under warranty, so there was no charge; otherwise, it could have cost over a thousand yuan. Since then, I've been extra careful not to drive through puddles on rainy days and to dry the interior corners immediately after washing the car. During monthly maintenance, I always remind the technician to check the insulation wiring, and I bought a hygrometer to monitor the environment inside the car. Simple changes in habits can significantly reduce the probability of failures, as new energy vehicles may save on fuel but are more fragile.
