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Leak Tester

Leak Testing System

Forward Technology has been integrating leak testing operations into production lines for over 40 years.  Testing parts for leakage has become crucial in a number of industries due to safety requirements, quality control issues, and time-saving demands.  We know how plastic parts react to leak test operations and our systems combine operator friendliness with detailed process information collection.  Our engineers can assist in analyzing your particular leak testing application.

Our PLC based leak testing systems employ a non-destructive test to ensure the integrity of the part. Air testing detects small leaks and eliminates the need for part drying. We offer several air testing methods:

  • Pressure decay
  • Vacuum decay
  • Chamber decay
  • Occlusion testing

Optional Features.

Please view our product options below. Click the option for a larger image.

Standard Features

Allen Bradley CompactLogix Controller Analyzer with custom programming complete with precision test logic and calibration capability. Completely expandable design allows simple upgrades of capabilities as the users needs change. Electronic control and precise repeatability provide quantifiable test results and elimiates operator decision making as seen with other test techniques such as immersion (dunk), soap solution, and visual gauge based testing.

16-Bit Analog to Digital Resolution offers ultra-fine resolution to detect even miniscule leakage quickly and with superb repeatability.

32+ Available Inputs/Outputs allow optimal flexibility in mating of the test analyzer to fixuring. Eliminates the costly requirement of adding an additional PLC to an Analyzer-Only when using multiple motion fixturing. System remains upgradeable for almost limitless control and testing possibilities.

Built-In Multi-Channel Transducer Capacity as each test system is constructed with the capability to optionally upgrade to 4 or more independently controlled testing channels with minimal increase in investment.

Allen Bradley PanelView Plus 7 - 600 Color 5.7in Touch-Screen Graphical Display simplifies parameter input and allows the following to be displayed digitally:

  • Fill / Stabilize / Test / Exhaust Timers
  • Current PSI
  • Measured Pressure Change
  • Measured Leak Rate (SCCM)
  • Part Counters
  • Ethernet Communication

User Programmable Windows for Test Pressure and Leakage Limits allow user to enter min/max values for critical parameters used to determine whether part has failed or passed.

Leakage Measurement in Standard Cubic Centimeters/Minute (SCCM) or Pressure Change enables user to display leakage in the format they prefer. SCCM is commonly used in automotive market segments. Appliance, medical, and electronic markets commonly use Pressure Change.

Compensation & Calibration Menus allow user to teach the tester what a known passed part will look like as well as how that part will look with a known (certified) leak rate orifice installed. Used most often when displaying leak rate in SCCM.

Multi-Level Passcode Protection limits parameter adjustment to qualified personnel only.

25 Test Program/Setup Memory allows storage for instant recall, minimizing tool change time.

Certified Leak Test Orifice allows user to manually adjust pressure settings with fine-tuning control.

Precision Sealed Industrial Electronic Pressure Transducer allows ultra-precise measurement of pressure changes typically to the nearest 0.0001 PSI. Sealed construction prevents damage to transducer even when liquid is present in test air lines.

Manual Precision Test Pressure Regulator allows user to manually adjust pressure settings with fine-tuning control.

Zero-Leakage Fill Valve(s) with Failsafe Supply Ventilation used at each discreet test channel. Unlike standard industrial valves, these precision valves are designed to prevent even miniscule leakage through the seals. However, bacause of wear, no seal lasts forever. Failsafe ventilation protects each test cycle against a false PASS resulting from leakage through the fill valve due to gradual seal wear or contaminant in the valve. During the Stabilize and Test steps (when the fill valve traps test pressure within the part), a secondary ventilation valve releases pressure from the supply side of the precision fill valve. By releasing this pressure, any possible leakage through the fill valve will result in test pressure being vented backward through the fill valve to atmosphere, causing a pressure drop during these steps which causes the test to fail (instead of re-supplying the test part with pressure were the supply side not to be vented to atmosphere).

NEMA 12 Enclosure offers complete protection of critical electronic and pneumatic system components in even the worse industrial environments.

Standard Off-The-Shelf Hardware minimizes downtime delays and expense as common Allen Bradley hardware and standard pneumatic components are the foundation for the system and are carried by most local distributors. Virtually eliminates the need to return the analyzer back to the factory for repair of proprietary circuitry.

Zero Force Cycle Activation Switches reduce operator fatigue.

Large Multi-Colored Indicator Lights provide a visual signal to operator of In Process or Pass/Fail status.

Sequence of Operation

  • 1.Operator loads part(s) to be tested into leak test fixture(s).
  • 2.Operator initiates both cycle activation switches.
  • 3.Leak test fixture(s) seal heads actuate to seal part(s).
  • 4.Operator is permitted to release cycle activation switches after all motions have been completed.
  • 5.Leak test analyzer pressurizes part(s) with compressed air.
  • 6.Leak test analyzer traps pressure within part(s) and vents pressure supply line to atmosphere.
  • 7.Leak test analyzer measures decay of pressure within part(s) and results are compared to user programmed limits.
  • 8.If test passes, a green indicator lights and the leak test fixture(s) seal heads retract from part(s), venting pressure to atmosphere.
  • 9.If equipped, optional part marker(s) actuate, imprinting character code on passed part(s).
  • 10.If test fails, a red indicator lights and the leak test fixture(s) seal heads remain closed, awaiting operator acknowledgment of the failure by again initiating the cycle activation switches.
  • 11.If equipped, no optional part marker(s) actuate.
  • 12.Operator removes tested part(s) from leak test fixture(s).