Project Description

Project Background

A leading global supplier specialising in high-performance sealing systems, fluid transfer systems and fuel and brake delivery solutions for the automotive industry initially approached our engineering team in the Czech Republic. With decades of expertise and a commitment to innovation, this long-standing partner sought to expand their production capabilities to meet increasing demand in the automotive sector.

The focus of their growth was on enhancing the manufacturing of plastic hose assembly variants. To achieve this, they required a state-of-the-art automated helium leak detection test line that seamlessly integrated upstream and downstream processes, ensuring both efficiency and precision in their production operations.

The Problem

This project presented unique challenges, particularly in the areas of data management, process automation and product variability. A critical requirement was the seamless collection, analysis and presentation of data to ensure full traceability across the production line. Also, given the variety of hose configurations, lengths and internal volumes, each requiring precise leak cycle time required a detailed vacuum pump down analysis and the selection of large vacuum pump configuration, the complexity of the task was significant.

Another key challenge was the automation of hose handling. The hoses needed to be fed automatically into the leak detection machines, accurately positioned and securely connected to perform specific leak test cycles without manual intervention.

Finally, ensuring secure and efficient data storage and transfer was a major focus. Leak test results and associated data needed to be stored locally on each machine while also being transferred to external networks for further analysis and integration with broader systems.

The Solution

To address the challenges of this project, our leak detection and automation engineers consult, support and develop a turnkey offering working closely and collaboratively with the customer to develop a tailored solution. By thoroughly investigating their requirements, we designed a flexible, fully factory-integrated system that could seamlessly expand as production demands increased.

At the core of our solution is an automated leak test traceability system. This system ensures that all test data, such as time, date and results is stored and linked to a hose-specific barcode identification. This approach enables a complete test history for every product, ensuring full traceability and compliance with industry standards.

To streamline operations and enhance efficiency, the automated leak test solution was built around a standardised methodology. By utilizing consistent fundamental components, PLC controls and a unified user interface across all machines, we delivered multiple benefits, including:

  • Reduced spare parts inventory for easier maintenance and cost savings
  • Improved serviceability to minimise downtime
  • Shortened lead times for faster deployment
  • Seamless factory integration to optimize workflows
  • Simplified training for operators and technicians, ensuring quicker onboarding

This holistic approach ensured the system not only met the immediate requirements but was also scalable and sustainable for future growth.

The Results

The project culminated in the successful implementation of a robust and highly efficient automated leak detection system. At its core was a cutting-edge hard vacuum double chamber helium leak test machine, equipped with advanced vacuum pump sets and a mass spectrometer, a system to accurately distinguish between pass and fail samples.

To support the complexity of the process, four dedicated automation stations were integrated into the system. These stations handled critical tasks such as loading, lifting, moving, marking and rotating the various-sized hose assemblies, ensuring precise positioning and secure connections for the specified leak test cycles.

The final solution was designed with scalability and long-term sustainability in mind. It offers the flexibility to accommodate future hose variants and new product introductions, while maintaining maximum reliability. The system’s design prioritises low maintenance and ease of serviceability, ensuring smooth operation and reduced downtime over its lifecycle.

Ultimately, the result is a well-developed and innovative automated leak test solution that achieved all the customer’s specification targets, supporting their growth and reinforcing their position as a leader in the automotive industry.

Summary

This project highlights the successful collaboration between our engineering team and a leading global supplier in the automotive sector to design and implement a state-of-the-art automated leak detection system. Facing challenges such as product variability, data traceability and process automation, our team delivered an innovative solution that met and exceeded the customer’s requirements.

Through close collaboration and a deep understanding of their needs, we developed a scalable and fully integrated system featuring a hard vacuum double chamber helium leak test machine, automated handling stations, and a robust traceability system. The standardised approach reduced complexity, improved efficiency and ensured long-term reliability, while also preparing the system for future growth and new product introductions.

The result was a transformative, future-proof solution that not only achieved all specification targets but also enhanced the customer’s operational capabilities and strengthened their position in the automotive market. This project demonstrates our commitment to delivering cutting-edge leak detection solutions tailored to the specific needs of our customers.