Automotive Parts Testing

1. Objectives and Core Applications

1. Cylinder and Cylinder Head Sealing Test

Test the airtightness of the combustion chamber to prevent compressed gas leakage, ensure engine combustion efficiency, reduce power loss, and lower emissions. This test is crucial for engine performance and commonly uses the differential pressure method or pressure decay method.

• Test Objective: Ensure the sealing between the cylinder head and cylinder is intact to prevent compressed gas leakage.
• Accuracy Requirement: The test accuracy can reach ±0.1%FS, accurately identifying minor gas leaks.

2. Valve and Crankcase Sealing Test

Ensure the sealing of the valves to prevent lubricating oil from entering the combustion chamber, thereby extending engine life.

• Test Objective: Prevent lubricating oil from entering the cylinder, avoiding impacts on combustion efficiency and engine pollution.
• Technical Points: Test the sealing of valves, valve seats, and valve guides to ensure no oil or gas leakage.

2. Solutions and Technical Points

1. Differential Pressure Method and Pressure Decay Method

Differential Pressure Method: Apply a certain pressure inside the engine cylinder and monitor the pressure difference between the inside and outside of the cylinder. If the pressure difference remains stable over a certain period, the cylinder is well sealed. If there is a leak, the pressure difference will change.

Pressure Decay Method: Fill the cylinder with gas and monitor the pressure change inside the cylinder. If gas leaks from the cylinder, the pressure will gradually decrease, and the size and rate of the leak can be determined by the speed of pressure decay.

2. Automated Testing Equipment

Using Huafu Engine Cylinder Head Sealing Test Equipment, which supports multi-channel parallel testing, can simultaneously test multiple cylinders, greatly improving testing efficiency.

• Single Test Cycle: ≤10 seconds, suitable for rapid testing in mass production.
• IP67 Standard Verification: Supports high waterproof standards, meeting testing needs in harsh environments.

3. Testing Process

1. Preparation:
   • Connect the engine to the testing equipment and ensure the cylinder and cylinder head are completely sealed.
   • Calibrate the testing equipment to ensure accuracy.
2. Pressurization:
   • Use inert gas (such as nitrogen) to pressurize the cylinder, typically to 2-3 bar.
   • Use the differential pressure method or pressure decay method to monitor the pressure difference inside and outside the cylinder.
3. Leak Detection:
   • If the pressure drops, it indicates a possible leak in the cylinder, and further confirmation of the leak location is needed.
   • Use gas leak detection instruments (such as gas detectors, foam liquid, etc.) to locate the leak point.
4. Data Recording and Analysis:
   • The automated equipment records test data and generates reports for subsequent analysis and decision-making.
   • Cloud Data Management: Enables remote monitoring and data storage, facilitating historical data queries and equipment maintenance.

3. Equipment Selection and Technical Parameters

1. Huafu Cabinet Type Leak Detector

• Equipped with high-precision pressure sensors, capable of detecting minor gas leaks.
• Supports multi-channel parallel testing, with a single test time ≤30 seconds, greatly improving production efficiency.
• IP67 waterproof rating, suitable for applications in humid and harsh environments.
• Automated operation: No manual intervention required, fully automated testing, reducing human errors and improving testing consistency.

2. Other Testing Equipment

• WF Series - Sixth Generation Detector: Provides specialized engine system leak detection equipment, supports helium leak detection, improving detection sensitivity.

4. Quality Control and Standards

• ISO 26262 Functional Safety Standard: This standard applies to the safety requirements of automotive electronic systems, ensuring high precision and reliability during the testing process, especially for safety-critical components such as engine systems.
• Testing Accuracy: ±0.1%FS, ensuring precise detection of minor leaks in cylinders, cylinder heads, and other related components, meeting high-quality control standards.

5. Practical Application Cases

• Gear Reduction Case
• Automotive Wiring Testing
• Automotive Taillight IP68

1. Objectives and Core Applications

1. Fuel Tank and Pipeline Sealing Test

Test the sealing of fuel system pipelines, connections, fuel tanks, and other components to prevent fuel leakage, ensure vehicle safety, and avoid fuel waste and fire risks.

• Test Objective: Test the airtightness of fuel pipelines, fuel tanks, valves, and interfaces to ensure no minor leaks (leak rate ≤50 Pa/min).
• Technical Points: High-sensitivity instruments are required during testing to detect minor leaks, especially in high-pressure environments.

2. Fuel Injector and High-Pressure Rail Sealing Test

Ensure the sealing of fuel injectors and high-pressure rails to prevent fuel leakage, ensuring injection accuracy and combustion efficiency.

• Test Objective: Ensure no leakage at the fuel injector and its connections, especially in high-pressure environments, to avoid impacts on engine performance.

2. Solutions and Technical Points

1. Leak Rate Test

To test the sealing of the fuel system, the micro-pressure difference method and gas pressure leakage method are used. By applying a certain pressure inside the system and monitoring pressure changes, the presence of leaks can be determined.

• Micro-Pressure Difference Method: Use high-precision sensors to detect pressure changes in the fuel system. By calculating the speed of pressure decay, the presence and size of leaks can be accurately determined.
• Gas Pressure Leakage Method: Inject air or nitrogen into the fuel system and use a flow meter to monitor the leakage gas flow, thereby assessing the system's airtightness.

2. AI Algorithm for Interference Filtering

To improve testing accuracy, AI algorithms are used to distinguish between fuel vapor interference and actual leaks, reducing the false positive rate to less than 1%. This is particularly important for high-precision testing, especially in complex fuel environments.

3. High-Pressure System Testing

New energy vehicles and high-performance vehicles often have high-pressure fuel systems, so testing equipment needs to support sealing tests for high-pressure rails and injection systems.

• Pressure Range: The equipment needs to adapt to a range from conventional pressure to high pressure (e.g., 300 bar), ensuring testing for all types of fuel systems.

3. Testing Process

1. Preparation:
   • Separate and seal the fuel system from the vehicle, ensuring all connection points (such as fuel tank, pipelines, fuel injectors) are sealed.
   • Calibrate the testing equipment to ensure its accuracy and reliability.
2. Pressurization:
   • Use inert gas (such as nitrogen) to pressurize the fuel system, typically to 2-5 bar, simulating the system's working pressure.
3. Leak Detection:
   • Gas Pressure Leakage Method: Monitor internal pressure changes using pressure sensors. If the pressure drops quickly, it indicates a leak. The leak location needs to be identified, whether it is at the pipeline connection, fuel injector, or fuel tank.
   • Micro-Pressure Difference Method: Detect gas flow changes using a precision flow meter or differential pressure sensor to monitor the leak rate. If the flow change exceeds the set threshold, it indicates a leak.
4. AI Algorithm and Data Analysis:
   • Use intelligent algorithms to analyze pressure change data in real-time, automatically identifying leak points and interference signals.
   • The false positive rate is less than 1%, improving testing accuracy, especially in complex environments.
5. Result Recording and Feedback:
   • Automatically record all test data, including test time, pressure changes, leak rate, etc.
   • Provide detailed leak reports and recommendations for subsequent repair and analysis.

4. Equipment Selection and Technical Parameters

1. WF Series - Sixth Generation Detector

• Application Scenario: Suitable for airtightness testing in fuel vapor environments, especially for high-pressure fuel systems and injection systems.
• Leak Rate: Supports detecting leak rates ≤50 Pa/min, capable of identifying minor leaks.
• AI Algorithm: Built-in intelligent algorithm, automatically filtering environmental interference, reducing the false positive rate to less than 1%.
• Pressure Range: Supports high-pressure environments for high-pressure rails and injector systems (up to 300 bar).
• Explosion-Proof Design: Complies with relevant explosion-proof safety standards, suitable for flammable and explosive environments.

5. Quality Control and Standards

• ISO 26262 Functional Safety Standard: Applies to the safety requirements of automotive electronic systems, ensuring high precision and reliability during airtightness testing.
• Testing Accuracy: Uses **±0.1%FS** high-precision sensors, ensuring precise identification of minor leaks during testing.

6. Practical Application Cases

• None

1. Objectives and Core Applications

1. Brake Master Cylinder and Pipeline Sealing Test

Ensure that brake fluid flow in the brake system is not affected by leaks, ensuring the system functions properly during emergency braking.

• Test Objective: Test the sealing of the brake master cylinder, brake pipelines, connection valves, and other components to ensure no brake fluid leakage.
• Test Requirement: Test whether the system pressure can remain stable, ensuring no leaks, especially in high-pressure environments.

2. Electronic Brake Booster Sealing Test

For new energy vehicles and high-performance vehicles, the sealing of the electronic brake booster is also a key testing point, ensuring the system's normal operation and safety.

• Test Objective: Verify the sealing and pressure resistance of the electronic booster system to prevent brake force reduction due to leaks.

2. Solutions and Technical Points

1. Dual-Pressure Method Testing

Use the dual-pressure method for brake system sealing tests, applying two different pressures and monitoring whether the pressure remains stable. This method can effectively detect minor leaks in brake pipelines and the system.

1. Step One: Pressurize the brake system to the set pressure (typically 10-15 bar) and perform stability testing.
2. Step Two: Apply a second pressure (e.g., high or low pressure) to the system and observe if there is a pressure drop. If the pressure change is too large, it indicates a system leak.

2. Leak Rate Testing

Through leak rate testing, measure the rate of pressure change in the system to determine if there is a leak. This method can detect minor leak points, especially in high-pressure environments.

3. Gas Sensors and Flow Meters

Use high-precision gas sensors and flow meters to monitor pressure and flow changes in the system to determine leaks. Real-time monitoring of flow changes can precisely locate leak points.

4. Pressure Holding Time Test

Apply a certain pressure to the brake system and monitor whether the system pressure remains stable over a certain period. If the pressure drop exceeds the set threshold, it indicates a leak point.

5. Helium Leak Detection

For minor leaks, the helium leak detection method can be used. Helium, due to its small molecular size and low interference with air, can precisely locate minor leak points. By injecting helium into the brake system and using a helium detector, the system can be tested to identify and locate the leak source.

3. Testing Process

1. Preparation:
   • Ensure the brake system is tightly connected to the testing equipment to avoid errors during testing.
   • Calibrate the testing equipment to ensure its accuracy and sensitivity.
2. Pressurization Stage:
   • Use inert gas (such as nitrogen) to pressurize the brake system, typically to 10-15 bar.
   • If testing an electronic brake booster, different pressure ranges can be applied based on the booster's working pressure.
3. Leak Detection Stage:
   • Use the dual-pressure method or pressure holding time test to monitor whether the system can maintain stable pressure after pressurization, observing if there is a significant pressure drop.
   • Use flow meters and gas sensors to detect the system's leak rate. If the flow exceeds the set threshold, it indicates a leak.
4. Helium Leak Detection Stage (Optional):
   • If no obvious leak points are found in the initial testing, helium leak detection equipment can be used. Inject helium into the system and use a helium sensor for precise detection to locate minor leak points.
5. Data Recording and Analysis:
   • Automatically record all test data, including pressure changes, leak rate, etc.
   • After data analysis, generate a report detailing the leak situation and provide repair recommendations.

4. Equipment Selection and Technical Parameters

1. HF Series - Fourth Generation Leak Detector

• Application Scenario: Suitable for airtightness testing of automotive brake systems, especially for brake master cylinders, pipelines, and electronic brake boosters.
• Testing Accuracy: Accuracy reaches ±0.1%FS, capable of detecting minor pressure changes, ensuring high-precision testing.
• Functional Safety: Supports ISO 26262 functional safety standards, suitable for testing safety systems such as brake systems.

2. Quality Control and Standards

• ISO 26262 Functional Safety Standard: This standard applies to the safety requirements of automotive brake systems and other electronic systems, ensuring no functional failures during airtightness testing.
• Testing Accuracy Requirement: To ensure the safety of the brake system, the testing accuracy should reach ±0.1%FS to detect minor leak issues.

3. Practical Application Cases

• Automotive Brake System Testing
• Gearbox Testing