Engine components and final assemblies

Multiple methods to check transmission

Exquisite welding techniques used with high pressure fuel pipes

Bài viết Leak Testing Solutions for Automotive Powertrains đã xuất hiện đầu tiên vào ngày Hystrong VN.

With this growing number of electric off-road vehicles, manufacturers will pose new challenges. These vehicles are subject to more extreme environmental conditions and hazards, and rigorous testing requirements are required for the battery packs that power these vehicles.

Leak testing is integral to supporting the evolving performance needs of EV battery

To ensure consistent performance and safety in the field, the internal components of an EV battery must be protected from physical damage that could result in leakage of liquid electrolytes from the battery. The electrolyte is a solution of lithium hexafluorophosphate salts. When this substance comes in contact with water, or even moisture present in the surrounding air, it can cause a chemical reaction that leads to a fire or even an explosion. If the anode and cathode in a cell, already very close to each other, come into direct contact with each other, it may cause a short circuit resulting in a fire.

With production pressure pushing for higher efficiency (reducing the weight of the battery box further), the internal and external structural components of the battery pack are getting thinner and thinner. With performance requirements increasing and this push towards lighter and thinner materials, leak testing must evolve to keep pace.

Leak testing electric vehicle batteries to IP67 standards

When we quote a leak test system to an EV OEM or supplier, we ask for a target leak rate, test pressure, and desired test cycle time. However, we also looked beyond the test station specifications to look at a field use case scenario.

We must consider that off-road vehicles can be subjected to very harsh conditions of use where the possibility of liquid or moisture penetration becomes a greater concern. Another caveat is that daily passenger vehicles may operate in areas of the country where annual and severe flooding occurs due to changing seasonal weather patterns.

Given these facts, the IP67 rating has become the standard for many electric vehicle manufacturers. Any device or assembly rated to this standard must be dust-proof and withstand up to 30 minutes of immersion in water up to a depth of 40 inches.

For battery pack internals such as the cooling system, high-volume flow or pressure leak testing with pressurized air is sufficient. To meet the IP67 standard (or an even more stringent standard, if we are concerned about water vapor ingress with fluctuations in ambient humidity and barometric pressure due to changes in altitude), we have to switch to test methods that can test reliably and quickly. even lower than the target leakage rate. For EV battery packs and cartridges, this means a vacuum or tracer gas fill test.

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Bài viết Leak Testing Solutions for EV Battery đã xuất hiện đầu tiên vào ngày Hystrong VN.

Get a rifle. These devices are usually charged with argon or nitrogen to prevent the ingress of moisture or oxygen. O-rings are critical to the functional operating life of the equipment and also present potential leak paths. Ingress of oxygen can cause internal corrosion. Any ingress of moisture can cause fog in the short term and mold growth in the long run. Mold over time can actually corrode the inside of the lens, resulting in permanently blurred images.

Variations in ambient temperature, humidity, and barometric pressure due to changes in altitude and between day and night create the perfect conditions under which water vapor can penetrate the seals and allow the gas to charge and leak out. In this case, the risk of penetration is higher than with equipment that is only exposed to liquid water. In these cases, IP67 testing with volumetric pressure decay leak testing may not be entirely sufficient for military industry.

For laser scopes, the critical element – the diode – is very susceptible to damage from heat, moisture, and contaminants if its outer housing is not kept sealed. So, how do we check that such a device does not leak gas charges or have a leak path that allows unwanted water vapor to enter when ambient operating conditions change in military industry?

This calls for vacuum leak testing

Instead of looking for evidence that pressurized air is leaking into a part, use vacuum leak testing, we instead check for evidence that the part is out of balance with internal gas.

The test portion is placed in a closed chamber having a volume around the smallest part. We then sucked the air out of the test chamber to create a vacuum instead of pressurizing the chamber with air. Vacuum is used to simulate pressure changes that can occur with higher altitudes etc.

Then we experiment with a two-step approach; first an overall leak test and then a minor leak test.

The two-step approach

The overall leak-sealed part (large hole) will pass the leak test well. That’s because vacuuming the test chamber empties the internal pressure or air intake at the same time. As a result, no pressure change will be measured during the actual test. We must first determine if the part has an overall leak before we can perform the critical minor leak test to determine pass/fail. This is done with a pressure decay test using a standard volumetric flask.

If the part passes the gross leak test, we then proceed with the fine leak test (step two). It measures a pressure change in the test chamber over an extended period of time. With a vacuum, any pressure change during the fine leak test indicates that gas is leaking into the chamber from the test part.

Another approach is to use the tracer gas method. Since a device like a scope is charged with argon or helium mixed with nitrogen, we will then evaluate any evidence of these gases leaking into the test chamber with a mass spectrometer.

Let’s talk about the right test for your leak test application

This is a brief introduction to how we can trust leak test scopes, laser scopes, and any other electronic or sealed device that must meet military-grade performance standards against the ingress of steam. If your components need to function under these extreme circumstances, we can help design a test solution to ensure they function at their best.

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Bài viết Leak Testing Solutions for Military Industry đã xuất hiện đầu tiên vào ngày Hystrong VN.

Innovative solutions for powertrain applications from motorcycles to pickup trucks

The transmission in motorcycles to pickup trucks makes the vehicle move stably. However, if the differential in the powertrain leaks, it will make the engine unstable, reduce the life of the vehicle, and endanger the driver.

CTS’s systems include pressure decay, vacuum decay, differential, and mass flow leak testers giving CTS the advantage. It can provide the global transportation industry with technology suitable for specific application technologies.

Leakage, flow, and air suspension measurement systems.

The transportation industry needs often forces users to test vehicles in all types of terrain and different environments before being used. High-pressure applications where the ability to compress air for pneumatic units to help to damp and adjust the vehicle’s chassis to the ground is a concern for safety issues. suitable for hydraulic flow measuring medium. Thirty years of custom system experience integrating a multitude of different hydraulic media provides CTS with many options for verifying the integrity and/or functionality of the components or systems being tested. safe.

Transportation is gradually being Innovated and driven by increasing emission regulations.

Large trucks emit a lot of waste that pollutes the environment. Because of that, the transportation industry is trying to design engines with the lowest emissions. Passage tests for emissions and gas leaks allow the industry to keep pace with government regulations.

Application-based experience coupled with the right combination of customized solutions and standard products has made CTS a global leader in the field of leak testers and functional testing systems. power. If the global shipping industry poses a challenge, CTS is ready to provide an innovative solution.

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Bài viết Leak Test Solutions for Many Transportation đã xuất hiện đầu tiên vào ngày Hystrong VN.

Effective solutions for green energy leak detection

The helium test is one of the most popular testing methods because the helium molecule is smaller than that of oxygen and hydrogen. This allows helium to pass through the smallest leaks and at the same time helium is non-toxic and non-flammable, ensuring safety for users. This test is conducted using systems containing MSLD (Mass Spectrometer Leak Detector). Methods used during helium leak testing include pressure testing and vacuum testing.

Pressure test using sniff and mark gas testing methods. Sniffing involves filling a test component with gas and using a probe to monitor or “sniff” the air around the component to detect the presence of gas leaks. During vacuum testing, the component is vacuumed either in the detector or in a separate system, depending on the part size. A spray probe is then used to bring helium to the surface to detect leaks.

Both test methods are used throughout the energy industry and the equipment can be adapted to meet different test requirements.

Mass Spectrometer Helium Leak Tests for Alternative Fuel Delivery and Storage

As gasoline prices continue to soar and strict regulations on emissions make the demand for clean energy sources increases. Alternative energy sources to gas are gradually becoming attractive energy sources, especially in the automotive industry. Capturing demand on CTS is ready to provide mass spectroscopic helium leak tests or pressure/flow-based solutions for energy storage and distribution systems.

Pressure Decay and Mass Flow devices for turbine leak detection

Wind turbines are one of the most popular types of energy today worldwide. A leaky wind turbine can cause performance and equipment life problems, resulting in cost and safety loss during use. Turbine leak detection solutions CTS’s range of mass flow meters include multi-test configurations and feature auto-calibration and storage for up to 99 pre-programmed test sequences.

Hydrogen fuel cell battery leak test

Hydrogen fuel cells use gas flow and diffusion to convert energy into electrical energy. Leaks can occur in cell blocks, plates or electrodes. However, by testing these components prior to assembly, it helps to prevent end product failure. From testing fuel cells and sub-assemblies to leaks and functional testing of fully assembled fuel cells, CTS has proven to be an innovative and reliable partner.

CTS has proven trend-setting offering innovative battery leak detectors and functional testing solutions that keep pace with rapid advancements in the energy sector. Our battery leak testing solutions include differential mass flow detection and helium mass spectrometry detection systems for advanced battery technologies.

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Bài viết Leak Testing Solutions For Energy Sector đã xuất hiện đầu tiên vào ngày Hystrong VN.

Advanced technology leak, flow, and explosion test equipment

The Sentinel family of devices are a versatile platform of standard products designed to provide a wide variety of solutions for a variety of test requirements. Applications ranging from lawn/garden equipment, power tools, kitchen faucets, and electronics are a few good examples of where CTS solutions are used to solve control problems. Application-specific leak, flow, and explosion testing.

Custom or standard inspection solutions

Regardless of the complexity of the application, CTS provides an effective inspection solution for each application in terms of quality and cost to meet your requirements. Product integrity and safety are of primary concern when products are purchased for the purpose of providing consumers with safe and quality products.

Helium leak detector for consumer goods manufaturing

The evaporator, condenser and compressor are excellent examples of CTS integrating helium leak detectors to ensure that the gas control system is operating at peak efficiency. The TracerMate II product reduces the overall cost and complexity of helium leak detectors by providing a standard solution.

For more than thirty years, CTS standard products or turnkey solutions have provided the consumer goods industry with a wide range of options that help ensure the integrity of products accessible to the public across the world. all over the world. CTS has the right combination of solutions to meet the growing needs of the consumer market.

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Bài viết Consumer Goods Leak Testing Solutions đã xuất hiện đầu tiên vào ngày Hystrong VN.

Leak testing can be performed on 100% of these components during production before or after filling the container with reagents. The testing process is different for each situation and we cover the requirements for both in this post.

The steps described are based on our experience using the Blackbelt Pro single- or multi-channel Sentinel Blackbelt Pro unit and CTS Connections for sealing.

Empty reagent cartridge leak test procedure

Start by sealing the empty toner cartridge to test

Accurate sealing is essential to ensure test accuracy. All cartridge openings are sealed with a Standard CTS Connector designed to seal around the cartridge’s outer diameter (CO30/31) or inner diameter (CI30/31) port(s) of the cartridge.

The empty reagent cartridge is then pressurized

The leak tester will pressurize the cartridge with compressed air/nitrogen which is regulated via one or more CTS Connections. The pressurization approach depends on the design of the cartridge: for example, some have separate but adjacent internal chambers within them. If leakage from one chamber to another is concerned, each component must be pressurized separately. Chambers not tested shall be ventilated to the atmosphere.

At the end of pressurization, the device may detect an improper pressure supply or an overall leak on the cartridge.

Check for gross and minor leaks in the reagent chamber

The next step is stabilization, where pressure is retained inside the pipeline to minimize the natural pressure loss of leak-free components due to expansion or creep, adiabatic thermal effects, and absorption capacity, which increases the separation of the final measured pressure loss/decay between the good and the reject part. At this stage, slightly smaller but still intact leaks on the cartridge chamber are detected.

Once the stabilization is complete, the device records the pressure loss/drop over a set test period and compares it with the min/max pressure limit to determine if a small leak is present or not.

Final step: Drain the foil compartments

After the end of the test, the pressure inside the cartridge or chamber is released for a specified discharge time.

If the cartridge has multiple internal chambers, the full test cycle is then repeated for each untested cavity associated with a different test port until all have been individually tested. These sequential tests check for leaks from one compartment to another and from one compartment to another.

Leak Test Process for Cassettes Filled with Reagent

Unlike empty cartridges, reagent-filled cartridges are sealed, making it impossible to pressurize or evacuate inside leak-free devices. These sealed cartridges require a relatively consistent amount of internal air inside the cartridge or the inner cavity in the foil seal to allow for accurate dry leak testing.

Instead of the positive pressure test used for empty cartridges, these tests are usually performed with negative (vacuum) pressure, testing the negative pressure of each pad by attempting to pull air inside the cartridge that came out through a leaky foil gasket.

Sealing the Filled Reagent Cartridge for Test

For an effective test, all foil-sealed cartridge holes should be sealed using a custom fixture with sealing tips surrounding each foil-sealed hole. If sealing just around the foil sealed areas is not possible due to the physical shape of the part or the small cartridge size, the entire cartridge is housed in a custom vacuum chamber designed to minimize the external mass surrounding the outside of the cartridge to maintain maximum sensitivity during both rough and fine leak testing.

In either case, the cartridge must be oriented in a way that allows the entire foil seal to come into contact with the trapped air head space inside, without the reagents coming into contact with the foil seal — otherwise, leaks can be covered.

Evacuation of the Sealing Heads or Vacuum Chamber and Gross Leak Test

Since there is only a finite amount of air inside the cartridge above the reagent inlet, an overall leak test must be performed first; otherwise, the leaf leakage can be so severe that all the space above the air is sucked out during the normal Fill step and the air will then decompose during the final test.

In the instrument, a fixed reference volume is vacuumed and its vacuum level is compared with the set minimum and maximum limits. The tester then releases this vacuum into the test chambers or washers and verifies the final level of vacuum provided against another limiter. If this is below the minimum vacuum limit, the cartridge will be discarded immediately, assuming there is an overall leak on the cartridge, as the space inside the test head or chamber is larger than normal.

For test efficiency, the gross leak testing sequence can be adjusted so the final delivered vacuum to the seal heads or vacuum chamber matches the specified fine leak testing vacuum level. Then the test may immediately proceed to fine leak detection.

Detecting Fine Leaks in Reagent – filled Cartridges

The isolating valve inside the test instrument closes, removing the reference volume from the small leak test volume and keeping the vacuum inside the vacuum seals or chambers for a defined stabilization time. Just like in empty cartridges, this is to minimize the natural vacuum loss of components that don’t even leak due to various factors. The vacuum level is measured to detect smaller but still coarse leaks

Following stabilization, the vacuum loss/decay is recorded over a set test time and compared to min/max decay limits to determine whether fine leaks are present. At the end of the test, the vacuum trapped is vented to the atmosphere and the user may release the seals or open the vacuum chamber to remove the tested cartridge.

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Bài viết How to Effectively Leak Test Reagent Cartridges đã xuất hiện đầu tiên vào ngày Hystrong VN.

Leak testing of assemblies across the entire vehicle – from headlights to taillights – is a key element in building reliable components. In working with eMobility companies around the world, I have noticed some common themes when it comes to leak detection.

Quality determination for new ingredient lists without standards

The most common challenge is determining what specifications are required and which technology is best used for testing. While some assemblies like cameras and LiDAR systems may rely on known testing for ratings like IP67, parts like EV batteries are newer territory and don’t have a real standard to work with.

The struggle to find the right balance between cycle time, test sensitivity, and cost combined with the fact that the choices made now may need to evolve when it comes to mass production actually starting, creates a lot of instability.

Collaboration is increasing and is occurring earlier in the process

To mitigate this uncertainty, we at CTS have seen that most eMobility manufacturers are adopting an increasingly collaborative approach with their test solution providers. In most cases, that means working together at earlier stages to understand part design and help establish initial specifications and conduct various tests to find out the right solution that meets your cost/ test sensitivity/ cycle-time balance requirements.

The good news is that cooperation between OEMs is also happening. This will help set reliability standards and set expectations for the performance of various EV and eMobility clusters.

Cost is driving the choice of leak test methods, but not always

Trying to manage costs is not unique to eMobility manufacturing. However, we’ve seen companies push the limits of air leak testing instead of looking for higher-cost alternatives — especially in complex assemblies like the battery tray. It is in fact the specification that determines the leak test technology. The specifications and possible process variables in the test environment are factors that need to be considered as a whole.

Using the battery tray as an example: manufacturing specifications generally tend to reduce leakage rates, and environmental conditions often affect test viability. While it may be desirable to test for air leaks at a lower cost, the right choice is more likely to be an alternative if the procedure and environmental conditions are not suitable for air leak testing.Choosing the right technology is something we work with our customers during pre-production testing. Since we offer a full range of solutions, we are not tied to a specific technology, but rather focus on directing our customers to a solution that is right for their application.

Also on the cost side, station footprint is increasingly important. There has been an even greater push to develop systems to maximize and optimize the use of floor space. That means that building the right leak test must take more factors into consideration than just the technology being utilized for the test.

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Bài viết Leak Testing Trends in eMobility Manufacturing đã xuất hiện đầu tiên vào ngày Hystrong VN.

HVAC leaks have many different causes. They can be the result of vibrations, such as in a car’s air conditioner. They can also be due to faulty seals, hoses or valve fittings, or even just normal wear and tear. The constant pressure can also create HVAC leaks. Due to these different causes, different tests may be required to determine the extent of a leak.

Everything leaks under pressure, so you need to detect and measure HVAC leaks starting at the factory by testing key components and making sure they don’t exceed maximum leak specifications. Micro leaks – i.e. small leaks of 0.5 grams per year – can also affect HVAC performance, which is why you need more precise leak testing methods.

Everything leaks under pressure, so you need to detect and measure HVAC leaks starting at the factory by testing key components and making sure they don’t exceed maximum leak specifications. Micro leaks – i.e. small leaks of 0.5 grams per year – can also affect HVAC performance, which is why you need more precise leak testing methods.

Different Leak Tests Have Different Sensitivities

Depending on the type of leak you are trying to detect, you have different leak test options.

For large leaks, the easiest and fastest approach is to use the bubble test. With the bubble or indentation test, you fill the part to be tested with air or gas, then immerse it in water, then look for air bubbles. This is the most basic type of leak detection and will detect larger leaks — typically 4.2 ounces (120 grams) of coolant per year or more.

There are other simple ways to identify leaks in HVAC systems, such as oil stains. Refrigerator coolant contains oil to lubricate the compressor, so if you see oil stains in joints, pipes, or near HVAC equipment, you most likely have a leak.

HVAC systems often develop leaks in the evaporator coils, making them difficult to detect. For more advanced and measurable forms of leak detection, you need a sniffer. A sniffer is a probe that detects the presence of tracer gas, such as leaking coolant. It is also an essential component in tracer gas testing, which is the most accurate way to determine HVAC leaks

Using Tracer Gas Testing for HVAC

HVAC leak testing begins in the factory. Components must be checked for potential leaks during manufacturing, including microscopic leaks that are difficult to detect. The best way to find small leaks is to use a tracer gas test.

If the presence of a larger leak is suspected, it is common practice to use a pressure decay test before the tracer gas test is used. Look for the overall leak first to ensure that a large amount of tracer gas is not released during the leak test, as it may affect the test results. Many CTS customers use TracerMate II because it can control the entire test sequence, starting with the overall leak test, ending with the tracer gas sequence, and all while looking for leaks micro.

During the trace gas leak test performed by TracerMate II, you will evacuate and fill the part with pressurized gas – usually helium – and then use a mass spectrometer gas analyzer to detect any gas leaks from that part. The measurement of trace gas in a controlled environment over time provides a leak rate, which is transmitted from the leak detector to the TracerMate.

Trace gas sniffing testing is the lowest-cost strategy for leak detection in HVAC components because it can detect smaller leaks than pressure decay testing. The final assemblies can be tested using helium or the formed gas accumulation test and the helium hard vacuum test, both of which are specific types of tracer gas tests. To test for leaks in welded fittings and connections, it is best to use a nitriding test.

Measuring Leaks with Nitrogen Purge Testing

The nitrogen purge test, also controlled by TracerMate II, is ideal for testing sub-assemblies and mounting points in HVAC systems. Designed by CTS, this patented tracer gas leak test uses a clamshell that fits around a pipe or joint to create a nitrogen barrier around fittings.

To test for leaks, the sealed clamshell is first submerged in nitrogen to purify the air and create a neutral test environment. The part under test is then vacuumed and compressed with a tracer gas, such as helium. The atmospheric chamber surrounding the seal then detects any helium leaking from the part into the nitrogen test medium using a mass spectrometer.

The nitrogen purge test is ideal for HVAC system testing because it is highly accurate and reduces false leak failures. It also can test for leaks as small as 0.5 grams of refrigerant loss per year. The clamshell design is available in stationary or handheld configurations, so it can test different HVAC systems.

Contact CTS to find the right HVAC leak test solution

There are many aspects to HVAC system leak testing and many types of HVAC leak testing. That is why it is essential to understand how to measure the different types of leaks and microleakages that can occur when inspecting HVAC assemblies and components. Contact the experts at CTS to learn more about HVAC leak testing and find the right leak testing solution for your application.

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