Leak testing (1) - immersion tester

Pawel Lipski / Bartlomiej Juszczyk, 2021.07.29, Lines & machines

Leak testing is one of the most common types of quality assessment processes in production, not only in the automotive industry. At ELPLC S.A. we have designed, built and implemented many types of leakage testers, incl. in the production of radiators, shock absorbers or engines. They are sometimes autonomous or part of a complete robotic production line.

Immerse leak testing

A special example worth presenting is the immersion tester for our client from Russia. It is designed to detect the location of a leak in a cast engine component. In simple terms, this process could be compared with searching for a leak in the inner tube of a bicycle wheel by immersing it in water and observing air bubbles. It tests castings for several references of blocks and engine heads & ndash; possible work on the next ones by making dedicated tools. By default, it has been tuned to four components with twelve tools to verify the set cells at the assumed pressure.

The station is operated by one operator, who both installs the component to the station, sets it up for the required reference and makes a visual assessment. The conversion of such a station is quick: it consists in removing the tools (both sides, top / bottom, front / back) and putting on others. The type of the tested element is practically irrelevant here. The stand is supplied with the hydraulic set, which is responsible both for the pressure of the seals and the lifting of the bathtub with water and the rotation of the component by +/- 180 degrees.

The pressing and immersion process is performed automatically and the operator controls the rotation. Seals can be made of a few selected materials, depending on the component and the rotations made on it, so as to ensure adequate life and quick replacement. On the operator's side, there is a security with a light curtain, which stops the movements at the station. From the rear, access is possible after opening the door secured with a bolt ensuring work safety.