Leak Tester for Filling and Exhausting Gases: Technical Analysis, Application Advantages and Industry Development

In modern industrial production and scientific research experiments, the sealing requirements for gas systems are becoming increasingly stringent. As the key equipment to ensure the sealing and safety of gas system, the integrated filling, exhausting and leakage testing machine plays an irreplaceable role in many fields by virtue of its integration of filling, exhausting and leakage testing functions, XVACUUM Technology (Jiangsu) Co. Provides strong support for the development of the industry.

First, the working principle and structural composition of the filling and exhausting leakage detection machine

(A) Core working principle

The working principle of the integrated gas filling and exhaust leakage detection machine integrates multi-disciplinary knowledge of gas dynamics, fluid mechanics and detection technology. In the filling process, the equipment will fill specific types and pressures of gases into the target system, such as pressure vessels, pipelines, sealing devices, etc. through the gas supply system. The gas rapidly fills the interior of the system under the action of pressure difference, so that the system reaches a predetermined air pressure state. The exhaust process, on the other hand, utilizes equipment such as vacuum pumps to pump the gas out of the system and reduce the internal air pressure of the system. In the exhaust process, the system residual air, impurity gas and other gases generated in the use of the process is discharged, for the subsequent leakage detection work or re-filling ready. Leak detection function is the core of the integrated filling and exhausting leak detection machine. At present, there are various leak detection methods in common use, such as helium mass spectrometry leak detection, differential pressure leak detection, halogen leak detection and so on. Taking helium mass spectrometry as an example, helium is filled into the system as a tracer gas because of its small molecule and strong diffusion ability. If there is a leak in the system, helium will escape from the leak, and the leak detector can accurately determine the location of the leak and the size of the leak by detecting the change of helium concentration in the surrounding environment. Differential Pressure Leak Detection is used to determine if a leak exists in a system by monitoring the change in pressure within the system over time. When there is a leak in the system, the pressure will drop abnormally, and by analyzing the pressure change curve, quantitative detection of the leak can be realized.

(II) Structural composition

The gas filling and exhausting leakage detection machine is mainly composed of gas supply system, vacuum exhaust system, leakage detection system, control system and connection device. The gas supply system includes gas storage tank, pressure reducing valve, flow meter and other components, which are used to store and accurately control the type, pressure and flow rate of filling gas. Different application scenarios may require different gases, such as inert gases for protection, specific reaction gases for process treatment, etc. The gas supply system can be flexibly switched and adjusted according to demand. The vacuum exhaust system consists of vacuum pumps, vacuum piping, vacuum valves, etc. It is responsible for pumping out the gas in the target system to create the required vacuum environment or to reduce the system air pressure. The performance of the vacuum pump directly affects the exhaust efficiency and vacuum degree. A high-performance vacuum pump can quickly discharge the gas in the system and improve the working efficiency of the equipment.

Leak detection system is the key part of the equipment. According to different leak detection methods, it is equipped with corresponding detection instruments and sensors. For example, if the equipment adopts helium mass spectrometry leak detection method, it will be equipped with helium mass spectrometry leak detector, which is able to carry out high sensitivity detection of very small amount of helium; if the equipment adopts differential pressure leak detection method, it will be equipped with high-precision pressure sensors, which can monitor the change of system pressure in real time. The control system adopts advanced programmable logic controller (PLC) or computer control system, and the operator sets the working modes and parameters such as filling pressure, exhausting time, and leakage detection parameters through the human-computer interaction interface. The control system can automatically coordinate the work of the gas supply system, the vacuum exhaust system and the leakage detection system, realize the automatic operation of the equipment, and monitor, record and analyze the data in the operation process in real time, and timely alarm and take corresponding protective measures in case of abnormality. Connection device is used to realize the reliable connection between the equipment and the target system, including all kinds of joints, hoses, seals and so on. Connection devices need to have good sealing and pressure resistance to ensure that there is no leakage in the process of inflation and exhaust and leakage detection to ensure the accuracy and reliability of the test results.

Second, filling and exhaust leakage detection machine application areas

(A) Automobile manufacturing industry

In the field of automobile manufacturing, filling and exhausting leakage detection machine has a wide range of applications. Automobile brake system, air conditioning system, fuel system, etc. have strict requirements for sealing. If there is leakage in the brake system, it will lead to insufficient brake pressure and affect driving safety; leakage in the air-conditioning system will lead to loss of refrigerant and reduce the cooling effect; leakage in the fuel system may cause fire and other serious accidents. The integrated filling and exhausting machine can quickly and accurately fill and exhaust these systems and detect leaks on the production line, ensuring that the relevant systems of each automobile have good sealing, and improving the quality and safety of automobiles. For example, after the automobile air conditioning system assembly is completed, the use of filling and exhausting leakage detection machine first vacuum the system to exclude the internal air and water, and then charge the appropriate amount of refrigerant, and leakage detection, to ensure that the air conditioning system's refrigeration performance and reliability.

(II) Aerospace field

The aerospace field requires high sealing of equipment and components, and any small leakage may lead to serious consequences. Filling and exhausting leakage inspection machine is used for the inspection of aircraft engines, fuel tanks, hydraulic systems, spacecraft sealing compartments and other key components and systems. During the manufacturing process of aircraft engines, by filling specific gases and conducting leakage testing, it can ensure that the internal gas circuit system of the engine is well sealed, prevent gas leakage, and improve the efficiency and reliability of the engine; as for the spacecraft sealing capsule, the filling and exhausting leakage testing machine is able to simulate the vacuum environment of space on the ground, and carry out stringent leakage testing of the sealing capsule to ensure the safety of astronauts' lives in space and the normal operation of the spacecraft. (iii) Electronics and electrical appliances industry

(III) Electronic and electrical appliances industry

In the electronic and electrical products, some equipment such as refrigerators, freezers, washing machines, sealing parts, as well as electronic chip packaging, vacuum tubes, etc., need to carry out sealing test. Filling and exhausting leakage detection machine can carry out rapid testing of these products to ensure that their sealing performance meets the requirements. For example, in the production of refrigerators and freezers, filling and exhausting the refrigeration system and leakage detection to prevent refrigerant leakage, improve refrigeration efficiency, while reducing pollution of the environment; in the process of electronic chip encapsulation, leakage detection to ensure the sealing of the chip encapsulation, to prevent the entry of external moisture, impurities and so on, which will affect the performance and service life of the chip.

(D) New energy industry

In the field of new energy, filling and exhausting leakage detection machine also plays an important role. In the production process of lithium battery, the sealing performance of the battery directly affects the safety and service life of the battery. Through the filling and exhausting leak detection machine on the lithium battery leakage, can be found in a timely manner the battery shell of the tiny leakage point, to avoid the battery in the use of the process of gas leakage led to bulging, fire and other safety accidents. In addition, in the manufacture of hydrogen fuel cells, energy storage systems and other equipment, filling and exhausting leak detection machine is also used to detect the sealing of gas pipelines, storage containers, etc., to ensure the safe and stable operation of new energy equipment.

(E) Scientific research experiment field

In scientific research experiments, many experimental devices and systems have strict requirements for gas sealing, such as vacuum experimental devices, chemical reactors, gas analyzers and so on. Filling and exhausting gas leakage detection machine provides researchers with a reliable means of detection, helping them to ensure the sealing of experimental devices, to ensure the accuracy and reliability of the experimental results. For example, in material science experiments, when researching the performance changes of materials in a specific gas environment, it is necessary to ensure the sealing of the experimental device to prevent external gases from interfering with the results of the experiment, and the gas filling and exhausting leakage detector can be used to carry out a comprehensive testing of the device before the experiment to ensure that the experiment is carried out smoothly.

Third, the technical advantages and contributions of XVACUUM Technology (Jiangsu) Co.

(I) Technological innovation ability

XVACUUM Technology (Jiangsu) Co., Ltd. has shown strong technical innovation ability in the research and development process of the integrated filling and exhausting gas leakage tester. The company's R&D team has thoroughly studied the principles and application characteristics of various leak detection technologies, and continuously explored new technical methods and processes to improve the performance and detection accuracy of the equipment. In helium mass spectrometry leak detection technology, by optimizing the mass spectrometry analysis system and signal processing algorithms of the leak detector, the sensitivity of detecting tiny leaks has been improved, and extremely tiny leaks can be detected; in differential pressure leak detection technology, the performance of pressure sensors and data acquisition and processing methods have been improved to achieve fast response and precise measurement of pressure changes, and the accuracy and efficiency of the leak detection has been improved. In addition, the company is also committed to applying advanced automation control technology and Internet of Things technology to the integrated filling and exhausting leakage detection machine. Through the introduction of automation control algorithms, the fully automatic operation of the equipment is realized. The operator only needs to set the relevant parameters, and the equipment can automatically complete a series of operations such as filling and exhausting, leakage detection, etc., which reduces the human error in operation and improves the work efficiency. Using the Internet of Things technology, the equipment can realize remote monitoring and data transmission, the user can view the equipment's operating status and detection data in real time through cell phones, computers and other terminals, so as to facilitate the timely detection of problems and processing.

(ii) Product customization service

XVACUUM Technology takes into full consideration the diversified needs of different industries and customers for the filling and exhausting gas leakage detection machine, and provides customized product solutions. The company's technical staff will deeply understand the specific application scenarios, detection requirements and special needs of customers, and carry out all-round personalized customization from the overall structural design of the equipment, the configuration of functional modules to the setting of detection parameters. For aerospace customers who require very high detection accuracy, the company can customize high sensitivity leakage detection system and high precision pressure control device; for automobile manufacturing customers who have a large production scale and need rapid detection, the company can design multi-station, highly automated filling and exhaust leakage detection integrated machine to improve the detection efficiency; for scientific research experiments, according to the needs of the experiments, the company can integrate the special gas supply system and data acquisition and analysis functions to meet the special needs of scientific research experiments. For scientific research experiments, special gas supply system and data acquisition and analysis functions can be integrated according to the experimental requirements to meet the special requirements of scientific research experiments. Through customized services, the company can provide customers with the most suitable equipment to help them solve practical problems and enhance their competitiveness.

(III) Perfect after-sales service system

XVACUUM Technology attaches great importance to after-sales service and has established a perfect after-sales service system. The company has a professional after-sales service team, which can provide customers with a full range of services. In the stage of equipment installation and commissioning, the technicians will go to the customer's site for installation and commissioning to ensure the normal operation of the equipment, and provide systematic training to the customer's operators to make them skillful in the operation method of the equipment and daily maintenance skills. In the process of equipment use, the after-sales service team regularly visits and maintains the equipment, finds and solves potential problems in time, and prolongs the service life of the equipment. When equipment failure occurs, the after-sales service team can respond quickly, through remote diagnosis or send technicians to the scene for maintenance, greatly reducing equipment downtime, to protect the customer's production and experimental work smoothly. In addition, the company also provides customers with equipment upgrading services, according to the development of technology and changes in customer demand, the performance of the equipment to improve and expand the function, so that customers can always use the advanced, reliable equipment.

Fourth, filling and exhaust leakage detection machine market status and development trend

(A) the current market situation

At present, with the continuous improvement of product quality and safety requirements of various industries, the market demand for gas filling and exhaust leakage detection machine shows a continuous growth trend. In the market, there are many suppliers of gas filling and exhaust leakage detection machine, and the competition is relatively fierce. With their advanced technology, long brand history and perfect sales and service network, some well-known international enterprises occupy a larger share of the high-end market, mainly serving in aerospace, high-end electronics and other industries with extremely high requirements for equipment performance and precision. XVACUUM Technology (Jiangsu) Co., Ltd. as a representative of the rapid development of domestic enterprises in recent years, through continuous increase in R & D investment, improve product quality and technical level, in the domestic market has gradually gained a firm foothold, and began to expand to the international market. With in-depth understanding of the local market demand, high cost-effective and good customized services, domestic enterprises have won the recognition of many customers in automobile manufacturing, new energy, electronic and electrical appliances and other industries, and their market share is gradually expanding.

(II) Development trend

Intelligent upgrading: In the future, the filling and exhausting gas leakage detection all-in-one machine will develop in the direction of intelligence. The introduction of artificial intelligence, machine learning and other technologies enables the equipment to automatically analyze the detection data, identify potential leakage problems and provide appropriate solutions. The equipment can automatically optimize the filling and exhausting and leakage detection parameters according to the historical detection data and real-time detection, improving detection efficiency and accuracy. At the same time, the intelligent equipment can also realize intelligent diagnosis of faults and predictive maintenance, discover possible faults and hidden dangers of the equipment in advance, carry out repair and maintenance in time, and reduce the failure rate and maintenance cost of the equipment.

Improvement of high precision and high sensitivity: With the continuous improvement of the sealing requirements of products in various industries, the detection precision and sensitivity of the filling and exhausting leakage detection machine have also put forward higher requirements. In the future, the equipment will adopt more advanced sensor technology, detection algorithms and signal processing technology to further improve the ability to detect small leaks, and be able to detect more subtle leaks, to meet the aerospace, semiconductors and other high-end areas of the stringent requirements of the sealing test.

Multi-functional integration and modular design: In order to meet the diversified needs of customers, the filling and exhausting leakage detection machine will integrate more functional modules, such as gas composition analysis, pressure fatigue test, vacuum drying and other functions, to achieve multi-purpose, providing customers with a more comprehensive solution. At the same time, the modularization design concept is adopted, so that the various functional modules of the equipment can be flexibly combined and replaced according to customer needs, which is convenient for upgrading and maintenance of the equipment and improves the versatility and adaptability of the equipment.

Green and energy-saving design: In the context of increasing environmental awareness, the filling and exhausting gas leakage detection machine will pay more attention to green and energy-saving design. Adopting environmentally friendly detection gases reduces pollution to the environment; optimizing the energy management system of the equipment reduces the energy consumption of the equipment; improving the resource utilization rate of the equipment reduces the generation of waste and realizes sustainable development.