SYSTEMS

Throughout the years we gathered a wide range of references at different, mostly Tier1 automotive suppliers and OEMs. Some of our machines operating actually on the field are able to perform tests with helium test-gas at a pressure of 380 bar. In case of any special requirements, we would be pleased to develop a new solution for it.

We are able to develop our machines to the requirements of our customers (from the structure, through the adaptation, to the controlling software and the visualization), but we can offer our standard systems with our standard control software and HMI as well.

Some information regarding our systems features:

A few of our machines in groups according to products:

Leak detection systems

Our main profile is to design and manufacture helium leak detection systems. Most of our systems have one, or more vacuum chambers where the product(s) can be placed during the test. With the help of the vacuum chambers the helium pollution from the surroundings can be isolated and in this way the systems sensitive is becoming higher, identification of smaller leaks is easier and more stable. Once the product is placed into the manual or automatic adaptation inside the vacuum chamber, it can be evacuated through the main pumping unit. Preliminary tests are performed to test the product and the adaptation for big leakage and once these tests are fulfilled, the leak detection can be started by pressurizing the product with helium on the required pressure, with the specified concentration*. 

Once the decision has been done, the pressure from the product will be released and it will be evacuated to avoid further helium contamination. The higher the testing pressure and, or the helium concentration is, the more can be saved by using our helium recovery unit (HRU), which is recovering most of the test gas at the end of the cycle. 

The detection range of these systems is between 9×10-4 mbar*l/s and 1×10-8 mbar*l/s. Our customers mostly use g/year for the climate systems. The leak rate of the product can be displayed in both units on the HMI. 

* Our HRU is able to generate a defined concentration mix. 

Helium Recovery Units (HRU)

When the test-gas is released from the product at the end of the cycle, the used Helium gas will be waisted and thrown out (usually outside the facility through a exhaust pipeline). Our helium recovery unit ensures the possibility to reuse the test gas for multiple times. Another huge advantage is that the helium bottle or bundle completely can be emptied before exchanging it. Without the HRU at least the same pressure as your testing pressure will have to remain in the bottle when it has to be exchanged. We have these units in different sizes, but the concept is very similar. A big balloon ensures to catch all the helium mix which is coming back from the leak detection system(s) and the circulation of the test gas ensures with the help of the concentration measurement a reliably constant helium test gas. Different kind of concentration levels can be generated (10-90% of Helium) and adjusted in our machines and once the conditions are met, a special compressor generates high pressure helium mix and transfers it into the high-pressure vessels.

Final pressures are changing mainly due to the different test requirements of the products. One system might have different output pressures, so high- and low-pressure systems can be supplied as well.

This can reduce the expenses and it is environmentally friendly because it helps to minimize your helium needs. The efficiency of our HRU’s is higher than 95%. 

Fuel Tube Testers

  • Semi-automatic test cycle according to specified recipes with manual adaptation of the product by the operator
  • Exchangeable adapter plate specific for test piece
  • Variable number (1 to 4) of test piece per chamber
  • Automatic recognition and recipe allocation is possible
  • Thanks to certified calibration tools, quality is assured and provable.
  • Chamber size optimized to customer needs
  • Optional accessories such as 2D scanner, printer, preferred PLC, etc.
Test gas pressure 32 – 380 bar
Throughput of the system
40-60 s
Handling
By operator

Ball valve-, Valve module- and Needle valve Testers

  • Semi- and fully automatic test cycle according to specified recipes with/without operator influence
  • Exchangeable adaptation/fixture specific to test piece
  • Automatic product recognition and recipe allocation is possible
  • 1 test piece per test chamber
  • Thanks to certified calibration tools, quality is assured and provable.
  • Chamber size optimized to customer needs
  • Optional accessories such as 2D scanner, printer, preferred PLC, etc.
Test gas pressure 100 mbar – 170 bar
Throughput of the system
18-130 s
Handling
By robot, or by manipulator and/or by operator
Additional features
LIN communication, Overall and single circle tests, etc.

Fuel Tank Testers with integrated HRU

  • Semi-automatic test cycle according to specified recipes with manual adaptation of the product by the operator
  • Exchangeable product type specific adapter plates (if required)
  • Automatic product type recognition through automatic barcode reading and recipe allocation is possible
  • 1 test piece per test chamber
  • Thanks to certified calibration tools, quality is assured and provable.
  • Chamber size optimized to customer needs
  • Optional accessories such as 2D scanner, printer, preferred PLC, etc.
Test gas pressure 100 – 500 mbar
Throughput of the system
65-120 s
Handling
By operator
The picture shows two lines, with three Helium leak detection systems

Compressor Tester Lines

  • Fully automatic test cycle according to specified recipes without operator influence
  • Automatic changeover with servo units
  • Recipe downloads from the High-level PLC
  • 1 test piece per test chamber
  • Thanks to certified calibration tools, quality is assured and provable.
  • Chamber size optimized to customer needs
  • Optional accessories such as 2D scanner, printer, preferred PLC, etc.
Test gas pressure 17 bar
Throughput of the system
24 / 12 s
Handling
Automatic by conveyor

Helium Recovery Units (HRU)

  • Ecofriendly, especially in view of environmental certifications according to ISO 14001.
  • Short payback period. Payback time depending on the consumption and pressure requirements
  • It can be a stand-alone or integrated system. A stand-alone system can supply multiple testers.
Operating pressure 1 – 400 bar
Balloon volume
2-10 m3 (or on request)
Efficiency
up to 95 %
Volume throughput
1-25 m3/h (or on request)
Helium concentration
10-95%