-
Differential pressure method: Determine the sealing
integrity by comparing good products with defective
products.
-
Flow method: Determine seal integrity by measuring the
flow rate of leaking gas.
-
Direct pressure method: Detect leaks by measuring
changes in gas pressure inside a sealed object. In
layman's terms, this method involves blowing or inhaling
air into the object and checking for changes to
determine if there is a leak.
Our leak detection equipment is suitable for leak detection of various products, especially for industries such as electronic products, medical devices, and automotive parts. The specific detection range can be customized according to the material, structure, etc. of the product.
Our leak detectors have undergone rigorous environmental testing and can operate stably under different temperatures, humidity and working environments. We also provide customized solutions for special environmental requirements.
Our equipment uses high-precision sensors to ensure the accuracy of the test results. Depending on the model, the accuracy can reach the detection of tiny gas leaks to meet the requirements of different application scenarios.
We provide comprehensive pre-sales and after-sales support, including equipment operation training, on-site commissioning, technical support, etc. Our engineering team can provide you with one-on-one technical consultation to ensure that you can quickly get started and use the equipment efficiently.
Our leak detection machines are designed with easy maintenance in mind, requiring only basic cleaning and calibration for daily use. We also provide regular maintenance services to ensure long-term stable operation of the equipment.
Possible causes:
1. Temperature change: Temperature changes in the test environment or the product being tested can cause gas expansion or contraction, affecting pressure readings and possibly causing negative leakage values.
2. Product or fixture deformation: The product may deform during pressurization, changing the internal volume, causing pressure changes and resulting in negative values.
Solution:
1. Temperature control: Keep the temperature of the test environment and the product under test stable to avoid pressure changes caused by temperature differences.
2. Equipment inspection: Regularly check the fixtures and pipelines to ensure that there is no deformation or damage and maintain the stability of the test volume.
Possible reasons:
1. Inconsistent operation: The operators' operation methods are not uniform, resulting in differences in test results.
2. Environmental factors: Environmental changes such as temperature and humidity may affect the stability of test results.
3. Equipment calibration issues: The equipment is not calibrated regularly or is improperly calibrated, resulting in reduced measurement accuracy.
Solution:
1. Unify operating specifications: formulate detailed operating procedures and train operators to ensure consistent operating methods.
2. Control environmental conditions: perform testing in an environment where environmental conditions such as temperature and humidity can be controlled to reduce interference from external factors.
3. Regularly calibrate equipment: calibrate the equipment according to the manufacturer's recommended cycle to ensure its measurement accuracy and stability.
Possible causes:
1. Power supply problem: Loose power connection or power module failure may cause the device to fail to start. BILIBILI.COM
2. Hardware failure: Failure of key components such as sensors and controllers may affect the startup of the device.
Solution:
1. Power supply check: Make sure the power supply of the leak detector is firmly connected, the power cord is not damaged, and the power module is working properly.
2. Component inspection: Check the working status of the key components of the leak detector, and contact the manufacturer for repair or replacement if necessary.
Possible reasons:
- Loose connections: Loose pipe connections or damaged seals may cause gas leaks.
Solution:
- Connection check: Make sure all pipe connections are tight and not loose or leaking.
- Seal check: Check the integrity of the seal regularly and replace it if damaged.
Possible causes:
Display screen damage: External impact or long-term use may cause display screen failure.
Solution:
Display screen inspection: Check whether the display screen is intact. If necessary, contact the manufacturer for repair or replacement.
In order to ensure the detection accuracy of the instrument, regular calibration is necessary. We provide regular calibration services for equipment, which can be calibrated on-site or in the factory according to customer needs. The equipment manual also provides simple self-calibration instructions for customers to operate by themselves.
1. Possible causes
1. Problems with the leak detection machine itself
Insufficient sensor accuracy of the detector: Aging of the pressure sensor or flow sensor will cause fluctuations in the measurement data.
Gas source pressure fluctuations: Poor pressure stability of the air pump or gas source (such as air pressure fluctuations, insufficient air supply) directly affects the repeatability of the inflation or vacuum process.
Inconsistent detector valve response: Differences in the switching time of the solenoid valve or control valve lead to deviations in the inflation/exhaust time or pressure control.
2. Test condition changes
Environmental temperature/humidity fluctuations: Temperature changes can cause gas volume expansion or contraction, and humidity changes may affect gas density or resistance of the leakage path.
Airtight fixture defects: There is a gap or uneven force between the workpiece and the fixture contact surface, such as looseness or deformation.
Workpiece defects: Material deformation, residual liquid or foreign matter (such as debris, oil stains) of the measured workpiece lead to temporary leakage changes.
3. Human factors
The leak detection instrument fixture is not strong enough or the position is inconsistent.
The leak detection test process is not standardized (such as the inflation time is not unified, and the test is started without waiting for the system to stabilize).
二、Solution
1. Equipment optimization
Regular calibration and maintenance：Calibrate sensors (such as pressure sensors, flow meters) periodically and replace aging parts (such as seals, valves).
Upgrade hardware：Use higher-precision sensors and faster-response valves (such as piezoelectric valves).
Improve gas source stability：Add a pressure-stabilizing valve, gas storage tank, or use a high-precision air pump to ensure a constant gas supply pressure.
2. Control the test environment
Constant temperature and humidity environment：Place the detection area in an environment with controlled temperature and humidity, or compensate for the effects of temperature/humidity through software algorithms (such as dynamically correcting the leak rate based on the ideal gas formula).
Workpiece preprocessing：Clean the surface of the test piece to ensure that there is no oil, dirt or foreign matter, and standardize the clamping process (such as using pneumatic clamps or torque wrenches to unify the clamping force).
3. Standardize operating procedures
Standardized operating manual：Clarify parameters such as inflation time, balance time, and detection cycle to avoid arbitrary adjustments by humans.
Automation replaces manual work：Use robots or automated tooling to achieve complete consistency in workpiece clamping and testing processes.
一、Possible reasons
1. Sensor nonlinear response
Detector range limitation:The linear range of a pressure sensor is usually limited and may exceed its optimal operating range at high pressures (e.g. >500 kPa), resulting in a deviation in the proportional relationship between the output signal and the pressure value (non-linear error).
Temperature Drift:The heat generated by the sensor increases under high pressure, and insufficient temperature compensation will cause zero drift or sensitivity change, especially when a constant temperature design is not adopted.
2. Sealing and leakage issues
Deformation of sealing materials: Sealing rings (such as O-rings) may be over-compressed under high pressure, resulting in permanent deformation or micro-leakage, especially low-hardness rubber materials (such as silicone) have insufficient resilience under high pressure.
Structural deformation: The detection cavity or pipeline undergoes slight elastic deformation (such as metal expansion) under high pressure, resulting in volume changes, which affects the accuracy of pressure decay calculation.
3. Air source stability and response speed
Insufficient air pump pressure supply capacity: The air pump needs to maintain a stable air supply under high pressure. If the air pump power is insufficient or the air circuit design is unreasonable (such as the inner diameter of the pipeline is too small), it will cause the charging time to be extended or the pressure to fluctuate.
Valve response delay: The air pump needs to maintain a stable air supply under high pressure. If the air pump power is insufficient or the air circuit design is unreasonable (such as the inner diameter of the pipe is too small), it will cause the charging time to be extended or the pressure to fluctuate.
3. Changes in physical properties of gas
Effect of gas compressibility: Gas deviates from the ideal gas state equation under high pressure (needs to be corrected by the van der Waals equation), resulting in an increase in the theoretical model of the pressure-volume relationship and the actual deviation. (such as the inner diameter of the pipeline is too small), which will lead to prolonged charging time or pressure fluctuations.
Adiabatic effect: During rapid inflation, the gas temperature rises (adiabatic compression), while the temperature gradually decreases during the detection process, causing non-steady-state interference in the pressure decay curve.
一、Solution
1. Hardware optimization
Use high-precision sensors:Use a sensor with a measuring range covering the high pressure section (such as 0-1MPa) and a linear error ≤0.1%FS, and integrate a temperature compensation module (such as PT100 temperature measurement).
Reinforced sealing design:Use special high-pressure sealing materials (such as fluororubber or polyurethane), or adopt metal sealing structure (such as cone seal); add redundant sealing ring design.
Structural anti-deformation design:The detection chamber is made of thick-walled metal (such as stainless steel 316L) and finite element analysis (FEA) is performed to verify the deformation, or the volume change is compensated by calibration.
2. Improvement of gas circuit and control system
Dynamic temperature compensation:By collecting temperature data in real time, the temperature term in the gas state equation is corrected (such as combining with the Clapeyron equation).
Pressure decay model optimization:A nonlinear leakage model (such as exponential decay fitting) is established for high-pressure gas to replace the traditional linear approximation algorithm.
3. Test process standardization
Extended equilibration time:Determine the thermal equilibrium time under high pressure through experiments (such as 30 seconds at 500 kPa) and force the waiting time in the program.
Segmented detection strategy:Different detection parameters (such as sampling frequency, leakage rate threshold) are used for high pressure (>500kPa) and low pressure sections to improve targeting.
-
Differential pressure method: Determine the sealing
integrity by comparing good products with defective
products.
-
Flow method: Determine seal integrity by measuring the
flow rate of leaking gas.
-
Direct pressure method: Detect leaks by measuring
changes in gas pressure inside a sealed object. In
layman's terms, this method involves blowing or inhaling
air into the object and checking for changes to
determine if there is a leak.
Our leak detection equipment is suitable for leak detection of various products, especially for industries such as electronic products, medical devices, and automotive parts. The specific detection range can be customized according to the material, structure, etc. of the product.
Our leak detectors have undergone rigorous environmental testing and can operate stably under different temperatures, humidity and working environments. We also provide customized solutions for special environmental requirements.
Our equipment uses high-precision sensors to ensure the accuracy of the test results. Depending on the model, the accuracy can reach the detection of tiny gas leaks to meet the requirements of different application scenarios.
We provide comprehensive pre-sales and after-sales support, including equipment operation training, on-site commissioning, technical support, etc. Our engineering team can provide you with one-on-one technical consultation to ensure that you can quickly get started and use the equipment efficiently.
Our leak detection machines are designed with easy maintenance in mind, requiring only basic cleaning and calibration for daily use. We also provide regular maintenance services to ensure long-term stable operation of the equipment.
1. Possible causes
1. Problems with the leak detection machine itself
Insufficient sensor accuracy of the detector: Aging of the pressure sensor or flow sensor will cause fluctuations in the measurement data.
Gas source pressure fluctuations: Poor pressure stability of the air pump or gas source (such as air pressure fluctuations, insufficient air supply) directly affects the repeatability of the inflation or vacuum process.
Inconsistent detector valve response: Differences in the switching time of the solenoid valve or control valve lead to deviations in the inflation/exhaust time or pressure control.
2. Test condition changes
Environmental temperature/humidity fluctuations: Temperature changes can cause gas volume expansion or contraction, and humidity changes may affect gas density or resistance of the leakage path.
Airtight fixture defects: There is a gap or uneven force between the workpiece and the fixture contact surface, such as looseness or deformation.
Workpiece defects: Material deformation, residual liquid or foreign matter (such as debris, oil stains) of the measured workpiece lead to temporary leakage changes.
3. Human factors
The leak detection instrument fixture is not strong enough or the position is inconsistent.
The leak detection test process is not standardized (such as the inflation time is not unified, and the test is started without waiting for the system to stabilize).
二、Solution
1. Equipment optimization
Regular calibration and maintenance：Calibrate sensors (such as pressure sensors, flow meters) periodically and replace aging parts (such as seals, valves).
Upgrade hardware：Use higher-precision sensors and faster-response valves (such as piezoelectric valves).
Improve gas source stability：Add a pressure-stabilizing valve, gas storage tank, or use a high-precision air pump to ensure a constant gas supply pressure.
2. Control the test environment
Constant temperature and humidity environment：Place the detection area in an environment with controlled temperature and humidity, or compensate for the effects of temperature/humidity through software algorithms (such as dynamically correcting the leak rate based on the ideal gas formula).
Workpiece preprocessing：Clean the surface of the test piece to ensure that there is no oil, dirt or foreign matter, and standardize the clamping process (such as using pneumatic clamps or torque wrenches to unify the clamping force).
3. Standardize operating procedures
Standardized operating manual：Clarify parameters such as inflation time, balance time, and detection cycle to avoid arbitrary adjustments by humans.
Automation replaces manual work：Use robots or automated tooling to achieve complete consistency in workpiece clamping and testing processes.
一、Possible reasons
1. Sensor nonlinear response
Detector range limitation:The linear range of a pressure sensor is usually limited and may exceed its optimal operating range at high pressures (e.g. >500 kPa), resulting in a deviation in the proportional relationship between the output signal and the pressure value (non-linear error).
Temperature Drift:The heat generated by the sensor increases under high pressure, and insufficient temperature compensation will cause zero drift or sensitivity change, especially when a constant temperature design is not adopted.
2. Sealing and leakage issues
Deformation of sealing materials: Sealing rings (such as O-rings) may be over-compressed under high pressure, resulting in permanent deformation or micro-leakage, especially low-hardness rubber materials (such as silicone) have insufficient resilience under high pressure.
Structural deformation: The detection cavity or pipeline undergoes slight elastic deformation (such as metal expansion) under high pressure, resulting in volume changes, which affects the accuracy of pressure decay calculation.
3. Air source stability and response speed
Insufficient air pump pressure supply capacity: The air pump needs to maintain a stable air supply under high pressure. If the air pump power is insufficient or the air circuit design is unreasonable (such as the inner diameter of the pipeline is too small), it will cause the charging time to be extended or the pressure to fluctuate.
Valve response delay: The air pump needs to maintain a stable air supply under high pressure. If the air pump power is insufficient or the air circuit design is unreasonable (such as the inner diameter of the pipe is too small), it will cause the charging time to be extended or the pressure to fluctuate.
3. Changes in physical properties of gas
Effect of gas compressibility: Gas deviates from the ideal gas state equation under high pressure (needs to be corrected by the van der Waals equation), resulting in an increase in the theoretical model of the pressure-volume relationship and the actual deviation. (such as the inner diameter of the pipeline is too small), which will lead to prolonged charging time or pressure fluctuations.
Adiabatic effect: During rapid inflation, the gas temperature rises (adiabatic compression), while the temperature gradually decreases during the detection process, causing non-steady-state interference in the pressure decay curve.
一、Solution
1. Hardware optimization
Use high-precision sensors:Use a sensor with a measuring range covering the high pressure section (such as 0-1MPa) and a linear error ≤0.1%FS, and integrate a temperature compensation module (such as PT100 temperature measurement).
Reinforced sealing design:Use special high-pressure sealing materials (such as fluororubber or polyurethane), or adopt metal sealing structure (such as cone seal); add redundant sealing ring design.
Structural anti-deformation design:The detection chamber is made of thick-walled metal (such as stainless steel 316L) and finite element analysis (FEA) is performed to verify the deformation, or the volume change is compensated by calibration.
2. Improvement of gas circuit and control system
Dynamic temperature compensation:By collecting temperature data in real time, the temperature term in the gas state equation is corrected (such as combining with the Clapeyron equation).
Pressure decay model optimization:A nonlinear leakage model (such as exponential decay fitting) is established for high-pressure gas to replace the traditional linear approximation algorithm.
3. Test process standardization
Extended equilibration time:Determine the thermal equilibrium time under high pressure through experiments (such as 30 seconds at 500 kPa) and force the waiting time in the program.
Segmented detection strategy:Different detection parameters (such as sampling frequency, leakage rate threshold) are used for high pressure (>500kPa) and low pressure sections to improve targeting.
Possible causes:
1. Temperature change: Temperature changes in the test environment or the product being tested can cause gas expansion or contraction, affecting pressure readings and possibly causing negative leakage values.
2. Product or fixture deformation: The product may deform during pressurization, changing the internal volume, causing pressure changes and resulting in negative values.
Solution:
1. Temperature control: Keep the temperature of the test environment and the product under test stable to avoid pressure changes caused by temperature differences.
2. Equipment inspection: Regularly check the fixtures and pipelines to ensure that there is no deformation or damage and maintain the stability of the test volume.
Possible reasons:
1. Inconsistent operation: The operators' operation methods are not uniform, resulting in differences in test results.
2. Environmental factors: Environmental changes such as temperature and humidity may affect the stability of test results.
3. Equipment calibration issues: The equipment is not calibrated regularly or is improperly calibrated, resulting in reduced measurement accuracy.
Solution:
1. Unify operating specifications: formulate detailed operating procedures and train operators to ensure consistent operating methods.
2. Control environmental conditions: perform testing in an environment where environmental conditions such as temperature and humidity can be controlled to reduce interference from external factors.
3. Regularly calibrate equipment: calibrate the equipment according to the manufacturer's recommended cycle to ensure its measurement accuracy and stability.
Possible causes:
1. Power supply problem: Loose power connection or power module failure may cause the device to fail to start. BILIBILI.COM
2. Hardware failure: Failure of key components such as sensors and controllers may affect the startup of the device.
Solution:
1. Power supply check: Make sure the power supply of the leak detector is firmly connected, the power cord is not damaged, and the power module is working properly.
2. Component inspection: Check the working status of the key components of the leak detector, and contact the manufacturer for repair or replacement if necessary.
Possible reasons:
- Loose connections: Loose pipe connections or damaged seals may cause gas leaks.
Solution:
- Connection check: Make sure all pipe connections are tight and not loose or leaking.
- Seal check: Check the integrity of the seal regularly and replace it if damaged.
Possible causes:
Display screen damage: External impact or long-term use may cause display screen failure.
Solution:
Display screen inspection: Check whether the display screen is intact. If necessary, contact the manufacturer for repair or replacement.
In order to ensure the detection accuracy of the instrument, regular calibration is necessary. We provide regular calibration services for equipment, which can be calibrated on-site or in the factory according to customer needs. The equipment manual also provides simple self-calibration instructions for customers to operate by themselves.
一、Equipment preparation
- Confirm that the detector has no damage on the outside and the power cord and air pipe are connected properly.
- Check whether key components such as pressure sensors and flow meters are working properly.
- Ensure that the equipment is well grounded to avoid static interference.
- Temperature: 10℃~40℃.
- Humidity: ≤85%RH (no condensation).
- Avoid strong vibration, strong electromagnetic interference and dusty environment.
- Standard test piece (for calibration).
- Sealed fixture (select according to the shape of the test piece).
- Cleaning cloth, dust-free gloves, gas source (such as compressed air or nitrogen).
二、Operation steps
- Connect the power supply and press the power button to start the device.
- Wait for the system self-check to complete and enter the main interface.
- Select the language, unit (such as Pa, kPa, cc/min) and detection mode (differential pressure method, direct pressure method, etc.).
- Install the standard test piece into the sealing fixture.
- Enter the "Calibration" menu and select "Zero Calibration" and "Full Scale Calibration".
- Follow the prompts and ensure that the calibration error is ≤±1%.
- Enter the "Test Settings" menu and enter the
following parameters：
- Test pressure: Set according to the requirements of the test piece (such as 0.5MPa).
- Pressure holding time: Usually 10~60 seconds.
- Leak rate threshold: Set according to the standard (such as 0.5cc/min).
- Save the settings and return to the main interface.
- Clean the surface of the DUT to ensure that there is no oil or dust.
- Install the DUT into the sealing fixture to ensure that the sealing ring fits tightly.
- Connect the air pipe to ensure that there is no air leakage.
- Press the "Start testing" button, the device will automatically inflate, maintain pressure and monitor the leakage rate.
- Observe the real-time pressure curve and leakage rate value.
- After the test is completed, the device will automatically determine the result (qualified/unqualified) and display it.
- Enter the "Data Management" menu to view the test records.
- Select the data to be exported and transfer it to a computer or cloud via USB or Wi-Fi.
三、Precautions
- Avoid overpressure testing and ensure that the test pressure does not exceed the maximum range of the equipment.
- Do not touch the sealing fixture during the test to prevent pinching or leakage.
- When using nitrogen, ensure good ventilation to avoid the risk of suffocation.
- Calibrate the equipment regularly (recommended once a month).
- Ensure that the test piece and fixture are clean before testing to prevent impurities from affecting the sealing.
- Avoid operating in extreme temperature or humidity environments.
- Abnormal pressure: Check whether the air source pressure is stable and whether the air pipe is leaking.
- Data fluctuation: Check whether the sensor is disturbed and recalibrate the device.
- No response from the device: Restart the device and check whether the power connection is normal.