Details

The High Pressure Leak Testing Machine is a precision-engineered, fully automated pneumatic test platform designed for high-accuracy, high-reliability leak detection in industrial components exposed to elevated internal pressures. Equipped with a sophisticated control ecosystem—featuring a PLC-based logic system and an intuitive 10” HMI touchscreen—the machine offers programmable test sequences, digital pressure monitoring, automated safety control, and data-driven process validation.

Designed to accommodate components ranging from compact solenoid valves to large pneumatic actuators, the machine enables high-pressure testing across a broad operational envelope (1.2 liters to 20 liters in volume). With flexible mounting and connection options, it is suitable for in-line quality inspection, batch testing, and destructive or endurance testing in sectors such as automotive, aerospace, railways, defense, and industrial automation.

The system’s rugged mechanical structure, high-grade instrumentation (WIKA, Haskel, Festo, Norgren), and built-in safety mechanisms make it ideal for high-frequency industrial use, ensuring compliance with international test protocols while maximizing operator safety and operational uptime.

Functional Testing Capabilities
The machine supports multiple distinct testing protocols, each optimized for specific applicationscenarios:
1. Leak Testing (Static Pressure Decay Method)
 • Operator defines the target test pressure, hold time, and maximum allowable pressure drop.
 • The system fills the DUT (Device Under Test) to the setpoint using the air booster.
 • The pressure is held and monitored for decay using precision transmitters.
 • Any drop beyond the set threshold flags a leak, with automatic pass/fail feedback.

2. Pressure vs. Time Profiling
 • Enables programmable pressure rise, holding durations, and decay measurements.
 • Real-time graphical plotting of the pressure profile helps identify material behavior under load.
 • Used for endurance, fatigue, and burst-pressure limit evaluation.

3. Direct Outlet Pressure Mode
 • Allows real-time control of pressure directly to the outlet port for tuning, calibration, or single-point validation.
 • Especially useful for testing components with dynamic internal valves, chambers, or flow paths.

4. Stepwise Pressure Ramp (Step Pressure Mode)
 • Multi-stage pressure increases in programmable increments.
 • Each step is held for a defined duration to simulate cyclic loading or operational pressure staircases.
 • Useful for parts undergoing fatigue testing or with pressure-dependent deformation characteristics.
Each mode is governed by a safety-verified logic sequence and offers manual override, digital diagnostics, and emergency handling capabilities.

Technical Specifications
 

            

              

                
Feature
                
Specification
              
            
            

              

                
Test Pressure Range
                
20 to 250 Bar (adjustable)
              
              

                
Component Volume Capacity
                
1.2 Liters (min) to 20 Liters (max)
              
              

                
Test Medium
                
Clean Dry Compressed Air / Nitrogen
              
              

                
Pressure Generation
                
Air-driven gas booster system (Haskel equivalent)
              
              

                
Dome-Loaded Regulator
                
Amplification Ratio: 44:1, Max Output: 5000 psi, Connection: 1/4" NPT
              
              

                
Air Receiver Tanks
                
6 Liters @ 350 Bar (High Pressure), 6 Liters @ 16 Bar (Low Pressure)
              
              

                
Analog Pressure Gauges
                
0–16 Bar and 0–400 Kg/cm², Glycerine-filled, SS316L, 100 mm dial (WIKA)
              
              

                
Digital Pressure Transmitters
                
0–400 Bar, Output: 4–20 mA, Accuracy: 0.25% FS, SS316 Body & Wetted Parts
              
              

                
Pilot Pressure Switch
                
Set at 300 Bar, 1/4" NPT
              
              

                
Control Panel
                
Touchscreen HMI (10”) + Schneider PLC
              
              

                
Solenoid Valves
                
Festo 3/2 & 2/2, Normally Closed/Open, 1/4” & 1/2” BSP, 220–230 VAC
              
              

                
Actuated Ball Valves
                
1/4” OD, Pneumatically actuated, Ham-Let make, NO/NC configuration
              
              

                
Safety Relief Valve
                
Range: 275–344 Bar, 1/4” tube OD, Spring-loaded fail-safe design
              
              

                
I/O Monitoring
                
Live diagnostic screen for digital inputs/outputs, valve states, and alarms
              
              

                
Safety Features
                
Emergency stop, pressure vent logic, tower light with buzzer (R/Y/G indicators)
              
              

                
Emergency Venting
                
Pneumatic pressure exhaust path with interlocked control
              
              

                
Mounting & Safety Cage
                
Table-mounted enclosure with interlock; optional grouted floor cage for larger DUTs
              
              

                
Compressed Air Requirement
                
6–8 Bar filtered dry air
              
              

                
Electrical Requirement (Control)
                
230 V AC (Solenoid valves), 24 V DC (Control logic & indicators)
              
            
          

Automation & Software
HMI Interface:
   - Responsive 10-inch touchscreen
   - Multi-language support (expandable)
   - Test configuration, monitoring, historical data access

PLC Control Logic:
   - Reliable, deterministic control for sequencing valves and monitoring sensors
   - Safeguarded interlocks prevent unsafe operation
   - Expandable for future I/O, data logging, and remote access integration

Data Visualization:
   - Real-time pressure vs. time plots
   - Clear test status indicators
   - On-screen pressure decay representation

Data Handling (optional upgrade):
   - Exportable test logs
   - USB/SD/Cloud connectivity options
   - Calibration record storage and automated alerts

Service & Maintenance Schedule
 • Before Each Use:  Visual inspection, check oil level and tightness of fittings
 • Weekly: Leak detection (spray or drop method), clean exterior and HMI screen
 • Monthly: Test pressure sensors for drift, verify system zeroing post-depressurization
 • Quarterly: Full booster inspection, re-torque adapters, check wiring, inspect dome regulator
 • Semi-Annual: Replace clogged filters, recalibrate gauges and transmitters, PRV testing
 • Annual: Overhaul of all pressure circuit components, update firmware if applicable
 • Every 5 Years: Major maintenance on booster, PRV, dome regulator, and system-wide leak test

Application Domains
 • Automotive Industry : Brake and clutch actuators, EGR valves, air suspensions
 • Aerospace & Defense : Pneumatic control valves, actuator canisters, launch interface subsystems
 • Railways : Door actuators, brake distributor valves, compressed air tanks
 • Medical & Gas Systems : Oxygen/nitrogen valve assemblies, pressure reducers
 • Heavy Industry & Automation : Pneumatic cylinders, regulators, control valves

Advantages at a Glance
 • High Precision: ±0.25% full-scale measurement with SS316L components
 • Total Automation: One-touch test cycles with no manual intervention
 • Industry-Grade Build: Built using globally trusted brands—WIKA, Norgren, Festo, Haskel, Ham-Let
 • Modular Platform: Future integration of burst testing, hydrostatic, or climate conditioning possible
 • Operator Safety: Interlocked enclosures, emergency shutdown, auto-venting logic
 • Application Flexibility: Compatible with a wide range of geometries and test setups
 • Documentation & Traceability: Can be integrated with barcode/QR-based test log systems