5 Reasons Why Your Business Needs multi channel air leakage tester？

Air Leak Testers

You can find more information on our web, so please take a look.

• LS-R902
• LS-R700
• LS-A / LU-80A
• LS-
• LS-R912
• LS-R740 (SS)
• LS-R740 (ZL)
• LS-R740 (SH)
• LS-R740 (WL)
• LZ-R155
• LZ-
• LS-R902EV

Sound vibration analyzer

• MVA-600
• MV-B

Helium, hydrogen and battery leak test

• LDS / LDS AQ / P(XL)
• Sentrac Strix
• ELT
• Cosmo’s Standard Helium Gas Recovery System

Flow meter

• AL-R302EV
• DF-231BA
• DF-R280
• AF-R221
• DF-241BA

Peripheral

• LM-1C / LM-1AH
• FM-2C
• QLC Series / LC Series
• MC Series
• G3-M / G3-H
• BU Series
• NL-S2 Series
• PCL-04
• LMC-120
• RC Series
• EO Ring Cord

Controllers

• PRV-700

Pressure gauge

• PT-105A-A / PT-103B-A
• PT-161A / PT-162A
• PT-141C / PT-142B-A
• DM-
• DP-340BA / DP-340B / DP-340

Cosmo Super Gel

• Cosmo Super Gel
• Gel gaskets
• Nobi Nobi Kun
• COSMO Extube

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Cosmo's Air Leak Testers

Information on Air Leak Testers

• Introduction flow
• Advantages of Air Leak Testers
• Features
• Examples of installation on machines

Test methods of Air Leak Testers

• Basic principle
• Overview of differential pressure sensor
• Comparison of differential pressure method and pressure change method
• Various test methods and their selection

Basics of setting Air Leak Testers

• Simple leak test
• Detailed settings for leak test
• Relationship between internal volume and leak
• Test timer settings
• Leak rates of gas and liquid
• Leak calibration

Fundamentals and applications of leak test technology

• Leak test and gas properties
• Cosmo's Calculation Tools
• Sealing technology

Support

• Warranty
• Inspection prices in Japan
• Repairs for old products
• Traceability
• FAQ

Company Information

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• Message / Vision
• History
• ISO Certification

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Leak testing in mass production lines for automotive and gas equipment components has traditionally been one of the bottleneck processes.
The method of visually checking for air bubbles by submerging the work in water after sealing is commonly used, but it has drawbacks such as possible oversights, the need for a drying process, and difficulty of automation.
Many alternative testers have been used, but they have shortcomings in terms of sensitivity, pressure resistance, running cost, handling, etc.
The differential pressure Air Leak Testers have been improved in place of the conventional methods and used as the most effective automatic leak testers.

Advantages of using Air Leak Testers

Automation / Labor saving

• Automates processing
• Saves manpower
• Easy operation, No skill required
• Improves work environment
• Easy maintenance

Improves quality

• Improves test performance
• Quantifies leak specifications
• Reduces defect rates
• Statistically processes and analyzes data

Reduces costs

• Lowers complaints
• Improves yield
• Requires no drying process
• Reduces test time
• Lowers running costs

Comparison of water-dunk test, bubble test and Air Leak Tester

Air Leak Tester Water-dunk test, Bubble test Automation
Automation
Burdens workers Numerical management
Data management possible, Improves test performanceP
Individual differences in detection Drying process
Not required
Required

Introduction of Air Leak Tester and leak specifications

To introduce Air Leak Tester, it is requiredl to set a quantified leak specification. It is necessary to determine what range of leak is acceptable by comparing with the conventional water-dunk test or by verifying under actual conditions.
It can also be determined with reference to past cases or specifications for similar works. The leak detection capability of leak testers depends on test conditions such as test time and test pressure. By using several non-leaking works and a reference leak (Leak Master) and performing some tests under different conditions, the actual performance of detection can be known from the data.

Leak units

• atm·mL/s or atm·mL/min
  The volume of air leaking into the atmosphere per second or per minute. “atm·” is often omitted.
  L μgr/s or μgr/min
  The weight of air leaking into the atmosphere per second or per minute.
  1 µgr (microgram) => 0.83 × 10-3 mL (1 atm, 20℃)
• Lusec
  Leak with a pressure increase of 1 μHg per second in a 1 L vacuum vessel.
  1 Lusec=1/760 mL/sec≒1.32×10-3 mL/s
• Torr・L/sec
  Leak with a pressure increase of 1 Torr per second in a 1 L vacuum vessel.
  1 Torr・L/s= Lusec≒1.32 mL/s
• Pa・m3/s
  1 Pa・m3 /s = 9.869 atm・mL/s
  1atm・mL/s = 1.013 × 10-1 Pa・m3/s

※ Leak represents the volume at atmospheric pressure

Types of leak detection methods

Water-dunk test, Bubble test

Pressurized air is sealed inside the work, and the work is then immersed in water or coated with soapy water to visually check air bubbles.

Tracer gas leak test

A gas (hydrogen, helium gas, organic halogen gas or chlorofluorocarbon gas) not present in the air is mixed with compressed air and sealed inside the work as a tracer gas to detect the gas leaking into the sealed container (chamber) containing the work with a gas detector (hydrogen leak detector, helium leak detector, etc. ).
(Applicable: Helium/hydrogen/battery leak test)

Flow measurement

Since the leak rate is equal to the flow rate, the leak can be measured by feeding air into the work through a micro flow meter.
(Applicable: Air Flow Tester AF-R221）

Pressure decay method, Vacuum decay method

Positive or vacuum pressure is applied. The pressure drop over time due to leak after sealing with a valve is then detected by a pressure gauge, pressure sensor, or pressure switch.
(Applicable: Digital Pressure Gauge DP-340BA）

Differential pressure method

This method uses a differential pressure gauge (U-tube, differential pressure sensor, etc.) instead of a pressure gauge to detect the pressure drop due to leak as a differential pressure with the master tank with high sensitivity.
(Applicable: Air Leak Tester）

Distortion detection method

This method is used for packaged goods such as confectionery and medicines (e.g., pillow packaging).
When a package containing air is placed in a capsule and the inside of the capsule is evacuated, the package expands, but if the package has a leak, it does not expand.
The expansion is detected as distortion.

Water-dunk test, Bubble test

• Very good
• Good
• Not so good
• Bad

Leak detection method Automation Detection capability Reliability Durability Versatility Economy Water-dunk test, Bubble test Tracer gas leak test Flow measurement method Pressure decay method,
Vacuum decay method Differential pressure method Distortion detection method

Unlike power supply, compressed air is generated onsite by the user and often the compressed air system is designed without accounting for measures such as air treatment, proper piping material selection, dimensioning the air distribution system correctly and spare capacity.

The result is a compressed air system that is very expensive to operate and does not help the user achieve productivity that the system is designed for.

Amongst all the above points mentioned, proper air treatment and using the correct material for piping, gain significance as these two factors result in a major cost impact to the user by generating leaks in the air distribution system. Compromising on either can lead to implications on cost and productivity, with untimely compressed air leak.

Many detailed studies have revealed that up to 20% of all compressed air produced is lost because of system leakage before it ever gets to the final user point. 

If poor system productivity isn’t a good enough reason to thoroughly check for air leaks , other factors that will press on its importance are reduced reliability, increased costs and the system’s unexpected shutdowns.

To improve the efficiency of the compressed air system, it is advised to be proactive in matters of maintenance services. Conducting routine air leak tests will help cut down energy costs and downtime, increasing the system's overall performance. Air Leak Test of your installation verifies and measures the reason for compressed air wastage, which will help you arrest the expensive leaks.

That said, compressed air leak testing is also a clean way to check if your compressed air system meets leak-tight specifications. 

Does your compressor have stop/start control? We tell you a simple way to estimate the air leakage amount in your system. First, start your machine when the air-run end-use equipment remains off. After some measurements, you can figure out the average time taken to load as well as unload the air compressor. Air leakages will make the compressor cycle off and on with a pressure drop.

To calculate total air leakage percentage, here is the formula:

Compressor capacity lost (percentage) expresses the air leakage amount. In a well-functioning system, the compressed air leakage percentage should be below 10%. As for poorly maintained machines, losses can be anywhere between 20-30% of air power and capacity.

Does your system have any other control strategy? If the receiver’s downstream has a pressure gauge, then leakage could be estimated. For this method to work, you will have to estimate the total system volume, comprising secondary air receivers downstream, piping, and air mains. After the machine runs for a while, it is brought to the usual operating system. Then, you have to consider the time your system takes for a further pressure drop (P2).

Compressed air leaks are an invisible enemy of a user’s operations and end up adding to the costs of production. Before you start with a new investment project on compressed air system please speak to an Atlas Copco air audit consultant to conduct an air leak test and review the existing installation, which will help you arrest the expensive leaks. Once this is done, if the existing system is unable to meet the air demand, start your discussion with a professional Atlas Copco Sales Engineer about your future requirements and expansion plans.

The company is the world’s best multi channel air leakage tester supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.