EARLY DECISION TOOL

The brand new ATEQ Early Decision Tool is an innovative solution designed to optimize leak detection efficiency in manufacturing. This tool works by analyzing pressure conditions early in the test cycle, allowing for faster rejection of faulty parts and significantly reducing overall testing time.

By integrating real-time analysis, the Early Decision Tool can cut cycle times by up to 50% without compromising accuracy.

EARLY DECISION TOOL : PRINCIPLE

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

early-decision-tool-graph-lack-stability

off-Catheters-assembly-line-f620

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

BENEFITS OF USING THE EARLY DECISION TOOL

  • Faster Testing

    Reduces cycle times by up to 50%, improving production efficiency.

  • Early Rejection

    Identifies faulty parts sooner, minimizing wasted time and resources.

  • Higher Accuracy

    Ensures precise leak detection without compromising quality control.

  • Cost Savings

    Lowers operational costs by streamlining the testing process.

  • Versatile Integration

    Compatible with various industries, including automotive, medical, and electronics.

EARLY DECISION TOOL : OPERATION

LEARNING MODE

learning-mode-reject-level-graph-1

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

PRODUCTION MODE

production-mode-graph-2-early-decision-tool

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 PARAMATERS FOR THE PRODUCTION PHASE

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

Decision taken at the end of cycle Number of parts (%) Total time needed per cycle (s)
Pr1 0 (0%) 0
Pr2 902 (90.2%) 81631
Pr3 53 (5.3%) 6731
Pr4 5 (0.5%) 817.5
Pr5 30 (3%) 6000
Early-decision default 10 (1%) 4000
Total 1000 (100%) 99179.5

INDUSTRY APPLICATIONS USING THE EARLY DECISION TOOL

  • Automotive

    • A/C Systems
    • Exhaust Systems
    • Gearbox
    • Fuel & Brake Lines
    • Reservoir Tanks…
  • E-Mobility

    • Fuel Cells
    • Battery Packs
    • Battery Tray
    • Hydrogen Tanks
    • Bipolar Plates…
  • Medical Devices

    • Catheters
    • Fluid Bags
    • Vials
    • Filters
    • Syringes…
  • Packaging

    • Bottle Cap
    • Cosmetic Packaging
    • Food Packaging
    • Plastic Bottles
    • Ink Cartridges
  • Consumer Electronics

    • Smartphones
    • Smartwatches
    • Speakers
    • Drones
    • Cameras…

EARLY DECISION TOOL IS COMPATIBLE WITH

EARLY DECISION TOOL : DOCUMENTATION

Contact ATEQ for sales information, general questions, press release information and marketing inquiries.