Customized airtight testing equipment designed specifically for production assembly lines
Customized, Universal Leak-Testing Equipment for Production Assembly Lines
(multi-industry, multi-part, rapid-changeover approach)
Table of Contents
- Universal Requirement Matrix
- Modular Test-Instrument Platform
- Universal Fixture / Quick-Connect Platform
- Universal Electrical & Data Interfaces
- Manufacturing & Quality-Control Milestones
- On-Site Commissioning & Acceptance Protocol
- Training, Spares, and Future Upgrades
- Universal Requirement Matrix
| Dimension | Typical Range | How to Specify |
|---|---|---|
| Part Category | Casting, plastic, metal tube, electronic housing, packaging | Tick box |
| Test Method | Pressure-decay / Differential-pressure / Mass-flow / Helium | Single or multi-select |
| Leak Rate | 1×10⁻² – 1×10⁻⁶ mbar·L/s | Enter value |
| Test Pressure | –0.9 bar – +10 bar | Min / max |
| Cycle Time | 5 – 120 s incl. loading | Target |
| Interface Style | Plain bore, thread, barb, quick-coupler, sealed part | Tick or describe |
| Line Height | 750 – 1200 mm adjustable | Measure on site |
| Enclosure Rating | IP30 / IP54 / IP65 | Match workshop |
| Data Link | None / MES / OPC / MQTT / Local CSV | Multi-select |
| Changeover Goal | ≤ 30 s or ≤ 5 min | State requirement |
- Modular Test-Instrument Platform
| Module | Universal Specification | Key Features |
|---|---|---|
| Pressure Source | Servo regulator 0–1 MPa | Instant switch positive / negative |
| Sensors | Diff. ±500 Pa, absolute 0–1 MPa | Plug-and-play, auto-ID |
| Valve Island | 24 V solenoid + proportional | Bus comms, hot-swap cartridges |
| Flow Meter | 0–50 sccm mass-flow | Optional, slide-in |
| Helium Module | Leak detector + vacuum pump | Drawer slide, removable |
| Chassis | 19-inch 4U / 6U sub-rack | Front service, tool-free swap |
- Universal Fixture / Quick-Connect Platform
| Sub-System | Universal Solution | Rapid Changeover |
|---|---|---|
| Fixture Base | Aluminum profile + T-slot | Dowel pins + quick-lock handles, 5 min swap |
| Quick Coupling | Modular cartridge | Cartridge replaced in 30 s, seals inside |
| Adjustable Support | Hand-crank lift 0–100 mm | Fits varying part heights |
| Floating Mechanism | Spring/air cushion ±2 mm | Reduces precision fixture cost |
| Seals | Standard O-rings 6–30 mm, 8 sizes | Color-coded, no mix-up |
- Universal Electrical & Data Interfaces
| Function | Hardware Interface | Software Configuration |
|---|---|---|
| Barcode / QR | USB / RS232 scanner | Auto-recipe call-up after scan |
| PLC Link | Ethernet/IP or Profinet | AO/AI + 16-point I/O mapping table |
| MES Upload | RESTful API + JSON | 5-line config |
| Remote Maintenance | 4G / Wi-Fi module | Web UI, no client install |
| Audit Trail | Local SQLite + auto CSV | ISO 9001 traceability |
- Manufacturing & Quality-Control Milestones
| Stage | Check Item | Universal Criteria |
|---|---|---|
| Machining | Key dimensions, GD&T | ±0.05 mm; Ra ≤ 1.6 µm |
| Pneumatic Assembly | Whole-circuit hold | ≤ 0.5 % drop in 10 min at 1.5× working pressure |
| Software FAT | Continuous dry run 2000 cycles | Zero faults, zero drift |
| Module Swap Test | Swap between any two chassis | No recalibration required |
- On-Site Commissioning & Acceptance Protocol
| Verification | Method | Pass Indicator |
|---|---|---|
| GR&R | 3 leak levels × 10 repeats | ≤ 10 % |
| Cycle-Time | 2 h continuous run | Actual ≤ 1.1 × target |
| Changeover Drill | Operator 3 full swaps | Average time ≤ target |
| Safety Interlock | Block light curtain 50× | 100 % stop |
- Training, Spares, and Future Upgrades
| Category | Universal Content | Delivery |
|---|---|---|
| Operator Training | Standard SOP, check list, video | On-site + live remote |
| Maintenance Training | Seal change 3 min, leak-cal 5 min | Hands-on test |
| Universal Spares Kit | 8 O-ring sizes ×10, filters ×5, fuses ×10 | Shipped with unit |
| Upgrade Headroom | 30 % slide & I/O spare | Later modules drop-in, no rework |