BYD recalls nearly 89,000 hybrid vehicles in China due to battery failure
Automotive giant BYD announced a major recall campaign involving 88,981 units of the Qin Plus DM-i sedan in Chinese territory. The safety call comes after the discovery of a serious fault in the battery modules, a situation that puts the safety of passengers at risk. The vehicles that need to return to the workshops were manufactured between January 2021 and September 2023. The plug-in hybrid car represents an important share of the automaker’s registrations in Asia, acting as a strong competitor against traditional combustion-powered cars.
The origin of the problem involves premature wear in high voltage cables
The official statement was registered with the State Administration for Market Regulation (SAMR), a Chinese entity that monitors the safety of consumer goods. Documents sent to the agency indicate that the defect arises from an assembly failure in the electrical harness, the part responsible for measuring the system’s voltage. This irregular assembly generates excessive mechanical tension on the wires inside the power compartment. Over time and normal asphalt vibrations, the cable structure deteriorates quickly, compromising the useful life of the entire assembly.
On the same topic: BYD recalls nearly 90,000 Qin Plus hybrid sedans due to serious battery system failure
Physical wear on the cables causes corrupted data to be sent to the Battery Management System (BMS). In the architecture of an electrified car, the BMS functions as a vital guardian that balances cell temperature and recharge to prevent early degradation. Upon receiving false voltage information, the central computer can trigger a safety mode and suddenly cut engine acceleration. If the vehicle is on a busy highway, this instantaneous loss of power increases the danger of serious accidents. The manufacturer also confirmed that the thermal imbalance resulting from the failure could, in extreme cases, start a fire.
Solution requires software reprogramming and replacement of physical components
To resolve the vulnerability, the brand’s engineers created a containment plan divided into two stages. The first phase uses internet technology embedded in vehicles to perform a remote update, a method called Over-The-Air (OTA). Sending this new data packet adjusts the on-board computer’s reading parameters. With the updated system, the car can detect small communication failures in the wiring harness in advance, triggering warnings on the driver’s panel long before any power cut occurs.
The second part of the repair requires an in-person visit to an authorized dealer. Trained professionals will carry out a visual and technical analysis of the high-voltage compartment to check the condition of the electrical harness. If mechanics find any signs of friction, wear or breakage in the wiring, the entire part will be replaced with a new one. The consumer will not pay any amount for the service, as the automaker has fully assumed the costs of parts and labor to ensure the safety of the fleet.
In order to organize the flow of customers in the workshops and guarantee the success of the recall, the company established a strict communication protocol:
More on this story: Serious battery failure forces BYD to recall 89,000 cars in China
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- Sending alerts directly to owners’ cell phones and messages on the multimedia center screen.
- Creation of a specific portal on the internet where the customer enters the chassis number to check if the car is on the list.
- Release in batches of the remote update, which only occurs when the car is stopped and connected to a fast internet network.
- Mandatory to schedule a time for physical inspection, preventing queues at dealerships.
Accelerated expansion of production exposes bottlenecks in quality control
The recall of the Qin Plus DM-i sedan adds to other recent episodes faced by the Asian giant. The dizzying increase in the pace of manufacturing has tested the company’s logistical limits, a common symptom in companies that scale their production very quickly. In October last year, the automaker had to recall 115,000 units of the Tang DM-i and Yuan Pro SUVs. The reason for that campaign also involved failures in the energy package that could result in flames, requiring a task force from the service network.
A little earlier, in September, a failure in the power converter led to the recall of 96 thousand copies of the Dolphin and Yuan Plus models, which presented a risk of overheating. Combining the three major recalls made in a short space of time, the number of branded cars sent back to the workshops breaks the barrier of 300 thousand units. These numbers highlight the difficulty of maintaining perfection on the assembly line while the company tries to meet extremely aggressive commercial targets in the electrical sector.
Pressure from regulatory bodies does not slow down the brand’s commercial advancement
China’s automotive ecosystem, today the largest hub for new energy vehicles on the planet, lives under strong government surveillance. Entities such as SAMR increased inspections at factories after several problems reported by consumers of various brands. Battery stability has become a national security issue for the Beijing government. Authorities demand that large corporations deliver impeccable products, in order to protect the image of Chinese engineering abroad and maintain the country’s dominance in exports in the sector.
Even with the sequence of safety calls, the manufacturer’s financial statement continues to display impressive numbers. Market data for October shows that the company sold 441 thousand cars globally, consolidating a significant increase compared to the previous year. The main driver of this financial success continues to be the family of plug-in hybrids, which accounted for 214 thousand units sold, a 31% jump in driver preference.
Learn more: Risk of engine blackout leads Nissan to recall 600,000 cars in Japan
All-electric models also showed robust performance, with 223,000 registrations in the same period. The strong outflow of hybrid cars shows that Chinese buyers want to save on electricity in the city, but do not give up the gas tank to guarantee long trips without the anxiety of recharging. This varied supply of engines allows the automaker to maintain its isolated leadership, generating such a high volume of profit that the million-dollar costs with recalls end up being absorbed without shaking investor confidence.
