1/27/2022

Delta Airtightness Test System Solution Enhances Efficiency in Sealing Inspections

Airtightness technology seals up the apertures of a product to avoid contact between the internal and external air. Today this technology is widely applied in different industries, such as for the body and engine cylinders of automobiles and motorcycles, railroad cars, airplane cabin, airtight windows, doors, and even home appliances like refrigerators. For all the products mentioned above, “airtightness” is a vital feature; and among all the steps of the manufacturing process, the sealing inspection is the last step to complete the process.

Before automated systems were introduced to industry, the conventional way of producing, assembling, and testing airtight products was done manually. For example, checking the position of fed-out O-rings, discarding disqualified items, mounting qualified O-rings onto fixtures, separating production lines, doing airtightness tests on both work stations, and more, were steps all done with manual labor. The biggest pain point for manual work is fatigue: error rates go up as human laborers gradually get tired over long working hours. Since airtight manufacturing requires a very high level of precision, especially the airtight testing part at the end of the process, any tiny error will make the whole airtight function fail. The implementation of automation and smart manufacturing is a must for the airtight process to achieve high efficiency and yield rate.

Delta provides the Airtightness Test System Solution to assist airtight manufacturers in constructing automated smart production lines. This solution uses three steps: first, examine if the position of the fed-out O-rings is correct and filter the disqualified units; second, mount the qualified O-rings onto fixtures and further separate the line into two workstations; and third, and most important, conduct the airtight test. Aside from the previous automated procedures, the system utilizes “compressed gas leak detection” for the airtight test. The test starts by injecting compressed air with a precisely controlled pressure and amount into the unit. When the air pressure reaches the predetermined parameter, the injection automatically stops. By observing if the pressure difference goes beyond the margin of error after a certain time, an operator can determine whether or not there is any air leakage.

Delta’s Airtightness Test System Solution employs the Compact Modular Mid-range PLC AS300 Series to manage the main logic control of the whole testing system. It then utilizes the Human Machine Interface DOP100 Series to display the system’s status and offer parameter setting function. Aside from the equipment at the managing end, the solution also achieves synchronized movement of the dual-manufacturing line by using the AC Servo Drive System ASDA-A2 Series; and for the testing part, the Standard Multifunction Pressure Sensor DPA Series is equipped to carry out highly precise and efficient tests.

Delta’s Airtightness Test System Solution brings the following benefits:
 

  • Smooth Production Line Control:
Delta’s Airtightness Test System Solution applies the Compact Modular Mid-range PLC AS300 Series with built-in position planning chart to complete fast position planning and path simulation. It can freely command the AC Servo Drive System ASDA-A2 Series motors with 20-bit encoders of the X and Y axis to execute the linear interpolation function which carries out smooth production line movement.

 
  • User-friendly Management Interface:
Delta’s Airtightness Test System Solution is equipped with the Human Machine Interface DOP100 Series with built-in LUA programming language and parameter set templates to achieve highly efficient programming and debugging.

 
  • Energy Saving for High Efficiency Test:
    The Standard Multifunction Pressure Sensor DPA Series units set at the testing end of the system are capable of quick-copying parameter sets allowing the operator to set up multiple units in a short time. The series also includes an energy-saving function that saves up to 20% of electricity consumption.

     
  • High Compatibility:
    The entire solution is built with Delta products, which makes the installation, usage, and maintenance easy and convenient.

Delta’s Airtightness Test System Solution not only fully automates the feeding, filtering, and mounting process of the components to raise productivity, it also achieves high product quality by securing the precision of the airtightness testing procedures.
 

News Source:IABG MKT