Leak testing is an essential stage in many manufacturing processes. Ensuring leak tightness is critical to meeting both safety and quality standards for many products across a wide variety of industries. If you're new to leak testing, understanding how to properly configure a leak test machine can help you avoid false failures, wasted time, and costly rework.
In this blog, we’ll walk you through the basic steps of setting up a leak test, with no prior experience needed, which includes entering test parameters, programming sequences, and troubleshooting. These fundamentals will help you build confidence as you begin leak testing on the production floor.
1. Enter Test Parameters
If your leak test instrument offers multiple leak test methods in one instrument, first you will select your leak test method (absolute pressure decay, mass flow, differential pressure decay, etc.). Then you will set your test parameters, including:
There are many variables that can affect your optimum leak test parameters, including application / function in the field, desired cycle time, volume of the part, material and design of the part, temperature of the part and the surrounding environment, and more.
Read the Blog Post: 7 Factors Affecting Your Lesk Test >>
2. Sequence and Preview the Test
Next, you will set up your test Sequence. This process is made easiest when using a highly visual, organized tool built into your leak test device.
The Sentinel IX5 features a powerful new Test Sequence Creator that simplifies the development of custom test process orders. You can build sequences with up to 50 events—or even more by linking sequences together. This allows you to combine multiple leak tests and functional steps in succession, whether you're running a single test with up to 10 tooling motions or executing a series of complex operations, including part presence checks, operator prompts, part marking, and more.
This creator tool offers intuitive mapping of the entire test Sequence in a graphic decision-tree format, making it easy to construct, edit and visualize the order of events (see below).
TIP: With the Sentinel IX5 test Sequence creator, you can also insert prompts with customizable text that appear for the operator at certain stages in the Sequence. For example, when a manual activity is required, the operator can execute and then simply click start to continue. This helps to streamline operator training, cut down on potential user error, and boost the efficiency of your test processes.
Want to Learn More About the New Sentinel IX5? Access the On-Demand Webinar.
3. Save the Program(s)
This is an important step in setting up your leak test. Using the Sentinel IX5 (below) as an example, you can save up to 250 test programs! Using the intuitive interface, you can easily name the program, customize that program’s Run screen, establish program-specific prerequisites, copy/paste programs and more —making setting up multiple tests and instruments more efficient!
4. Troubleshoot
Troubleshooting is an inevitable part of leak test setup and maintenance. Sometimes, you may only realize the need for troubleshooting when good parts begin failing the test due to part clamping/seal wear, supply line or part contamination in the test air pathway, etc. However, with the Sentinel IX5, CTS wanted to make troubleshooting as quick and proactive as possible.
Using the Sentinel IX5, users are immediately alerted to problems with the test and can easily access instructions on what to do next with the new, detailed Notifications view (below).
This view includes QR codes to allow the user to access detailed troubleshooting steps and recommendations directly using their smartphone. This provides the most efficient means of diagnosis and corrective action, reducing downtime and getting your test back up and running quickly.
Simplify Test Setup with CTS' Sentinel IX5!
The Sentinel IX5 can integrate multiple air leak test methods within a single instrument (pressure/vacuum decay, flow, blockage, ramping and volume verification tests), making it a game-changer for manufacturers looking to optimize and streamline their operations.
Ready to improve your leak test? Contact us to discuss the Sentinel IX5!