⚙️ 1. Diagnostic & Testing Zone
Core Function: System fault detection, data analysis, and performance validation.
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Digital Multimeter (CAT III/IV Rated): Measures voltage, current, and resistance in high-voltage circuits. Essential for checking battery leakage, sensor integrity, and controller stability. Select auto-ranging models with anti-burn protection .
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EV-Specific Diagnostic Scanner: Dedicated tools like BYD DS3000 or NIO FDR2 for reading fault codes, resetting battery management systems (BMS), and calibrating motor controllers. Must support CAN bus protocols for Chinese EVs .
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Insulation Resistance Tester (Megohmmeter): Tests high-voltage cable insulation (0.1MΩ–1TΩ range) to prevent short circuits. Critical for post-repair safety checks .
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Oscilloscope: Analyzes waveform integrity in motor controllers and inverters. Detects anomalies like voltage spikes or signal noise .
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Battery Analyzer: Tools like Midtronics EXP-1000 assess State of Health (SoH), capacity degradation, and cell balancing needs. Supports lithium-ion (LiFePO₄/NMC) chemistries .
⚡ 2. High-Voltage Safety Zone
Core Function: Safe handling of 400–800V traction batteries and powertrains.
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1,000V-Rated Insulated Tool Kit: Includes torque wrenches, screwdrivers, and pliers with dielectric coatings. Prevents electrocution during live component work .
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Personal Protective Equipment (PPE):
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Class 0 Insulation Gloves (tested to 36,000V) + leather protectors.
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Arc-flash face shields and fire-resistant coveralls.
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Voltage-testing pens to verify de-energized circuits .
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High-Voltage Safety Tester: Validates isolation monitoring and residual current device (RCD) response times (<20ms) .
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Battery Lift Platform: Hydraulic trolley with 500kg+ capacity for safe removal of underfloor battery packs (e.g., BYD Blade Battery) .
🔋 3. Battery Repair & Maintenance Zone
Core Function: Battery pack servicing, cell replacement, and performance optimization.
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Battery Module Tester: Identifies weak cells via internal resistance (ACIR) and voltage deviation analysis. Example: Fluke BT500 .
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Cell Balancing/Equalizer: Active balancers (e.g., QNBBM-24S) for LiFePO₄/NMC packs. Corrects voltage mismatches (±0.01V accuracy) to extend lifespan .
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Pulse Battery Repair Station: Devices like Yuasa PCR-3000 desulfate lead-acid auxiliary batteries and recover capacity in Li-ion packs .
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Coolant Refilling System: Vacuum-based tool for refilling battery thermal management coolant without air pockets .
🔧 4. Mechanical & Powertrain Zone
Core Function: Motor, gearbox, and suspension repairs.
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Electric Motor Tester: Diagnoses winding shorts, hall sensor failures, and bearing wear. Compatible with PMSM motors used in BYD e-platform 3.0 .
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Torque Wrench Set (5–200 Nm): For precise tightening of motor mounts and suspension components. Includes E-sockets for high-torque bolts .
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Bearing Puller/Installation Kit: Removes seized motor bearings without damaging rotors .
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Portable Crane (500kg): Lifts motors/gearboxes during drivetrain overhauls .
🔌 5. Charging System & Infrastructure Zone
Core Function: Charger diagnostics and installation support.
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EVSE Analyzer: Tools like Metrel A1632 simulate vehicle connections, test RCD tripping, and validate PWM signals in Type 2/GB/T chargers .
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Thermal Imaging Camera: Monitors overheating in charging ports, cables, or battery terminals during stress tests .
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Portable Charger Tester: Verifies output voltage (200–920V DC), current, and communication protocols (CCS/CHAdeMO) .
📦 6. Support & Safety Equipment
Core Function: Workspace safety and efficiency.
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Insulated Tool Storage Cabinets: Prevents moisture damage and maintains dielectric properties .
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Fire Suppression System: Lithium-ion-rated extinguishers (Class D) + battery fire blankets for thermal runaway events .
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Fume Extractors: Filters soldering/ welding fumes during PCB repairs .
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EV Lift (9,000lb Capacity): Two-post lifts with high-clearance adapters for underbody access .
📊 Tool Summary Table
|
Zone |
Critical Tools |
Key Specifications |
|---|---|---|
|
Diagnostics |
EV Scanner, Megohmmeter, Oscilloscope |
CAN bus support, 0.1MΩ–1TΩ range |
|
Battery Repair |
Cell Equalizer, Pulse Repair Station |
±0.01V balancing, Li-ion/lead-acid modes |
|
High-Voltage Safety |
Insulated Tools, HV Gloves, Battery Lift |
1,000V rating, 500kg capacity |
|
Charging Systems |
EVSE Analyzer, Thermal Camera |
Type 2/GB/T compatibility, 920V DC range |
💼 Operational Recommendations
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Training & Certification: Partner with BYD/NIO for technician certification in high-voltage systems .
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Tool Calibration: Schedule quarterly calibration for multimeters, torque wrenches, and insulation testers .
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Software Subscriptions: Maintain updates for OEM diagnostic software (e.g., BYD StarLink) .
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Safety Protocols: Implement Lockout-Tagout (LOTO) procedures and mandatory PPE for HV work .
⚠️ Critical Compliance Note: Traction battery repairs require manufacturer authorization to avoid warranty voidance. For non-certified shops, limit services to module replacement (not cell-level) .
By integrating these zones and tools, your workshop will achieve full coverage for Chinese EV repairs—from battery health to motor diagnostics—while prioritizing technician safety and repair accuracy. 🔧
