Isometric view of cart-mounted leak test system with large stainless steel rectangular vacuum chamber with open door Closeup of large stainless steel rectangular vacuum chamber with open door built to leak test A/C hose assemblies

Global manufacturer of automotive A/C components required a leak test system that could accommodate A/C  hoses in a single test chamber. The customer needed two test volumes (inner and outer) on hoses with a wide range of sizes and connection interfaces. Testing requirements included an electrical pressure sensor test and an occlusion detection requirement

We engineered a custom leak test system using the helium hard vacuum leak test method and featuring a custom valve manifold to perform dual-volume leak testing. The universal vacuum test chamber could accommodate multiple sizes of hoses and interchangeable connectors. 

  • Universal vacuum test chamber for a wide variety of test parts
  • Automated chamber open and close with safety light curtains
  • Automated calibration with helium supply and calibrated leak
Industry:
Automotive A/C Systems & Components
Application:
Leak testing A/C hose assemblies
Production Volume:
Medium to high
Tracer gas:
Helium
Controller System:
Proprietary PLC  with 8" touchscreen, system status lights and buttons,
and software with fully automated and manual mode operation of the test sequence with built-in interlocks for manual operation
Leak Test Method:
Helium hard vacuum
Leak rate:
1.0 x 10-4 atmcc/sec
Throughput:
~1 part per 60 seconds
Cycle Time:
50 seconds, including load/unload
Test Pressure:
3.92 Mpa (569 psig)
Configuration:
Portable cart
Chamber:
Custom 36" H x 28" W chamber with horizontal sliding door with penuematically operated door
clamps
Leak Detector:
LDS2010 Mass Spectrometer
Pumping System:
2 stage rotary vane pump for part evacuation prior to charging and for leak testing the inner tube


Reference Materials

What Should I Include In My Leak Test System Request for Proposal (RFP)
Presentation: A Process for Selecting and Implementing the Optimum Leak Test Method

Application Notes

Technical Note A: Production Leak Testing: What, Why and How

Videos

Production Leak Testing Solutions Showcase