Helium Leak Testing System
for Automotive HVAC Safety Valves
A fully automated system for functional and seat tightness testing of safety valves used in automotive HVAC systems. The system processes multiple valve variants completely changeover-free within an extremely short cycle time.
8 s
Helium leak detection Cycle time per component
10-5
mbar·l/s leak rate detectable (helium)
95 Bar
Operation pressure
100 %
Fully automatic. No manual intervention during the test procedure
The Challenge
Manual Testing Process Throttles the New Production Line
Because the customer uses several different valve variants, they faced a logistical and operational challenge: the new testing solution had to be flexible enough to handle various functional and tightness tests without any setup time or manual operator intervention.
At the same time, the automotive industry’s process speed requirements were demanding: the required cycle time was just 8 seconds per component to prevent bottlenecks in the production line throughput.
The Requirement: A high-efficiency testing system capable of evaluating different valve variants without manual setup changes during fast line cycles (8 seconds/part). It had to verify both mechanical functionality and ultra-low helium leak rates at pressures of up to 140 bar.
The Solution
Customized Test System – Seamlessly Integrated into the Line
A tailor-made helium leak testing system was developed to test different component types fully automatically and without any changeover effort. By parallelizing and optimizing the testing processes, the system reliably achieves the demanding 8-second cycle time per part while maintaining maximum measurement precision at extremely high test pressures.
Test Methods
Functional testing and seat tightness verification
Test Medium
Helium (fine leak detection)
Test Pressures
95 bar and 140 bar (tightness); 160±10" bar" (functional)
Handling
Fully changeover-free operation during variant switches
Threshold Leak Rates
1×10^(-5) " mbar"⋅"l/s" at 95 bar helium pressure 5×10^(-5) " mbar"⋅"l/s" at 140 bar helium pressure
Component Types
Various safety valve variants
Cycle Time
8 seconds per component
Eingesetzte Prüfverfahren
Diese Verfahren wurden für diese Anlage kombiniert und sind je nach Anforderung auch einzeln einsetzbar.
Leak Testing
Detection of even the smallest leaks at high test speeds to ensure leak-tightness and proper function.
Typical Applications:
- Safety-critical components
- Tests of service life and durability
- High quality standards
- Ensuring compliance with current environmental requirements
10 -10 mbar*ltr/sec
Leckrate
Functional test
Typical Applications:
- to verify the specified functionality
- for quality assurance in production and end-of-line testing
- to check electrical, mechanical or mechatronic functions
- during the validation of assemblies and complete systems
- to detect functional faults prior to delivery or commissioning
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Helium Leak Testing System
- 8 s helium leak detection cycle time per component
- 10⁻⁶ mbar·l/s detectable leak rate (helium)
- 5 bar test pressure with 10% helium
Zone Melting System
Get Expert Advice
Do you have questions or are you unsure which system is the right fit for your requirements? No problem. We are happy to advise you personally and work with you to find the ideal solution for your application. Benefit from our years of experience, an honest assessment, and professional guidance — tailored to your needs and with no obligation.
Contact person
Michael Landgraf
Managing Director
- m.landgraf@aprotec-gmbh.de
- +49 9353 982460-11