OPTIMIZE LEAK TESTING CYCLE TIME

The Early Decision Tool optimizes leak testing by quickly identifying defective parts before the full test cycle is completed. It works by analyzing pressure variations early in the process, allowing immediate rejection of faulty components. This proactive approach minimizes testing time, reduces waste, and enhances overall efficiency. By integrating this tool, manufacturers can streamline production while maintaining high-quality standards. Although it requires precise calibration, its ability to detect failures sooner makes it an essential addition for industries that demand fast and accurate leak detection.

Early Decision Tool Principle

Leak test a large volume requires a long stabilisation time before the test phase. The objective of the early-decision tool is to shorten this time, allowing to take a decision earlier and gain time. The long original cycle is divided into a succession of N short cycles.

For example (with N=5): Pr (original): FILL + STABILISATION + TEST + DUMP becomes:

• Pr1: FILL + STABILISATION + TEST
• Pr2: STABILISATION + TEST
• Pr3: STABILISATION + TEST
• Pr4: STABILISATION + TEST
• Pr5: STABILISATION + TEST + DUMP

LEARNING MODE

Thanks to a learning phase done on thousands of produced parts, the measurement curves are collected, and an uncertainty zone is defined.

PRODUCTION MODE

After defining the uncertainty zone, the production mode is initiated:
Pr1 is launched, followed by Pr2.

If the value measured in Pr2 is in the grey zone, no decision can be taken (undecided), Pr3 is launched.
If the value measured in Pr2 is in the green zone, the part is leak-free, A decision is taken: PASS and the test is stopped.
If the value measured in Pr2 is in the red zone, the part is leaking, A decision is taken: FAIL and the test is stopped.

The same procedure is followed until a decision (PASS or FAIL) is taken.

Conformity parameters are added to limit the influence of unpredictable phenomena that can interfere with the measurement, such as a human intervention, an external air flow, a sudden change in temperature.

During the production mode if these parameters do not fall in between the imposed calculated limits for every one of the programs, a warning message is displayed.

EXAMPLE

Parameters

Pr (original): FILL (20s) + STAB (150s) + TEST (10s) +DUMP (20s) = 200s
We can divide into N = 5 with S(1) = 4s S(N) = 26.5s

• Pr1: FILL (20s) + STABILISATION (4s) + TEST (10s)
• Pr2: STABILISATION (26.5s) + TEST (10s)
• Pr3: STABILISATION (26.5s) + TEST (10s)
• Pr4: STABILISATION (26.5s) + TEST (10s)
• Pr5: STABILISATION (26.5s) + TEST (10s) + DUMP (20s)

Production phase: 1000 parts

If the early-decision tool is not activated, the total time
needed to test the 1000 parts is equal to 1000 times the duration
of Pr (original) (200s) = 200000 s

If the early-decision tool is activated = 99179.5 s
(Hypothetical distribution)

Optimized time = 50.4%

On average, the test passes from 200s to around 99.18s