Customer
A leading U.S. manufacturer of automotive and electric vehicles.
Application
Quick leak test connectors that can seal off all ports on the battery pack. These connection profiles include electrical header connections, coolant ports, and de-gas valve connections.
Challenge
The typical battery electrical header connections found on battery packs present a significantly greater sealing challenge than circular ports. As a result, achieving full and consistent seal engagement can be more difficult. This caused an unacceptably high level of maintenance and downtime and a poor first pass yield percentage with their current tools.
Project Goals
- Improve test quality, consistency, and accuracy.
- Connectors made from non-conductive connector housing materials
Solution
FasTest custom-designed a set of non-circular and nonconductive electrical header leak test connectors for the electrical header connections. Beyond the battery pack, FasTest provided quick connect leak test connection solutions for the broader powertrain system including associated motors, inverters, and coolant lines.
Results
The customer achieved all production objectives including improvements in first pass yield and overall battery production through-put, as well as decreased test tool rig and de-rig time. Superior durability of the FasTest seal solution had the added benefit of significantly reducing maintenance downtime needed to replace worn seals, a tremendous value in a high-volume production environment. The customer is now partnering with FasTest to drive consistent and repeatable leak testing practices globally across all plants.
