The Chinese automotive industry faces a new safety episode involving the world’s largest new energy vehicle maker. BYD has officially announced the start of a recall campaign covering 88,981 units of the Qin Plus DM-i model, one of the brand’s most popular plug-in hybrids. The measure responds to a flaw detected in the manufacturing process of the battery pack tray, a critical component for the structural and thermal integrity of the energy storage system. The corrective action covers vehicles produced during a specific period, extending from January 2021 to September 2023, according to documentation submitted to regulatory bodies.
The technical problem identified lies in the quality of production of the tray that houses the battery cells. Segundo the manufacturer’s internal investigations and the supervision of Administração Estatal of Regulação of Mercado (SAMR) of China, the defect may compromise the sealing and protection function of the system. In situations of continuous use, this structural fragility increases the risk of thermal runaway, a chemical phenomenon that can lead to uncontrollable overheating and, in extreme cases, the vehicle fire, putting the physical integrity of the occupants at risk.
The notification to Chinese regulatory authorities demonstrates the company’s proactive move to mitigate risks before serious incidents become widespread. Lithium battery safety remains a focal point of attention in the global energy transition, and manufacturing failures of protective components such as trays require immediate intervention to maintain consumer confidence in electrified technologies.
Software repair and update strategy
To resolve the technical vulnerability found in the Qin Plus DM-i models, BYD engineering developed a repair protocol divided into two distinct steps. The first phase involves a remote update, known as OTA (Over-the-Air), targeting the battery management system (BMS). The new software has been calibrated to increase the sensitivity of the monitoring sensors, allowing the vehicle to detect anomalies in cell voltage or temperature with greater accuracy and speed.
If the updated system identifies any irregularity in the battery’s operating parameters, an alert notification will be immediately displayed on the driver’s instrument panel. Esta message instructs the owner to urgently contact an authorized dealer for a detailed physical check. The use of connectivity technology allows the automaker to monitor the health of the fleet in real time, speeding up the identification of units that have a latent defect in the tray.
The second stage of the process consists of physical inspection at authorized network workshops. Técnicos specialists will perform integrity tests on the battery pack tray. If the inspection confirms that the component is outside of safety specifications or has damage that compromises the seal, BYD will replace the entire battery pack free of charge. Esta measure ensures that no costs will be passed on to the consumer, reaffirming the manufacturer’s responsibility for the production defect.
Context of previous recalls and production volume
This is not an isolated event in the brand’s recent expansion trajectory. The current announcement adds to other safety procedures carried out in recent months, indicating greater rigor in quality inspection as production scales. Recentemente, the company had already summoned owners of the Tang DM-i and Yuan Pro models, totaling more than 115 thousand vehicles that required technical checks. The recurrence of recalls, although common in the modern automotive industry, highlights the logistical and industrial challenges of maintaining standards of excellence on assembly lines operating at maximum capacity.
In a previous episode, around 96 thousand units of the Dolphin and Yuan Plus models were also subject to recall due to faults in the electric steering assistance controller. On Naquela occasion, the risk involved the possibility of a fire in the power steering control unit (C-EPS), which could result in loss of control of the vehicle. The accumulation of these events totals more than 300 thousand vehicles recalled for repairs in the second half of this year alone, a significant number, but which must be analyzed from the perspective of the company’s total sales volume.
Market performance and impact on sales
Despite the technical challenges faced on the production line, BYD’s business performance continues to break historic records. The most recent data from October shows that the manufacturer reached the mark of 500,526 units sold in a single month. Este massive volume statistically dilutes the percentage impact of recalls compared to the total fleet in circulation. However, the plug-in hybrid (PHEV) category, of which the Qin Plus DM-i is a part, recorded a slight negative swing, with sales of 310,912 units, while pure electric vehicles (BEV) grew to 189,614 units.
The response of the Chinese financial market and consumers to these recalls has been closely monitored. Transparency in the call process and agility in implementing solutions via software have been fundamental to maintaining the brand’s image. The ability to resolve complex hardware issues through prior software diagnostics demonstrates the evolution of the electronic architecture of modern vehicles, transforming the way preventive maintenance is viewed in the industry.
Regulation and security at China
The role of Administração Estatal of Regulação of Mercado (SAMR) has been decisive for the standardization of safety in new energy vehicles in China. The agency has intensified surveillance over battery manufacturers and automakers, demanding more rigorous testing protocols before vehicles are approved. Regulatory pressure aims to ensure that the rapid growth of the electric vehicle industry does not come at the expense of road safety and consumer protection.
The interdependence between battery cell manufacturers and automakers creates a complex chain of responsibility. In the case of BYD, which verticalizes its production by manufacturing its own batteries (Blade Battery), responsibility is centralized, which facilitates defect traceability, but also concentrates reputational risks. The effective resolution of this Qin Plus DM-i recall will serve as an important test for the resilience of the company’s quality processes in the face of an increasingly demanding global market.
