System and method for detecting leakage of a chassis

Abstract

The present invention discloses a system and method for detecting leakage of a chassis. The method for detecting leakage of the chassis includes: mounting the chassis on a plate member, wherein the plate member is disposed on a sealed chamber; and fluidly connecting the internal space of the sealed chamber to a water tank through a pipe such that the bottom end of the pipe is below the water surface in the water tank. The method further includes: determining, for example by visual observation, whether bubbles are formed at the bottom end of the pipe due to pressurized air flowing into the pipe. The method also includes: determining the presence of leakage in the chassis due to the flow of pressurized air between the chassis and the sealed chamber before flowing into the pipe.

Description

Technical Field

[0001] The present invention relates to leak detection, and more particularly to systems and methods for detecting leakage in a chassis. Background Art

[0002] The Ingress Protection Rating, defined by the International Electrotechnical Commission, defines the protection of the mechanical and electrical enclosures of a chassis against intrusion, dust, accidental contact, and water. For example, IP6X represents the standard for classifying a chassis as dustproof, and IPX7 represents the standard for classifying a chassis as waterproof. Both the IP6X and IPX7 ratings require the chassis to be leak-tested during the production process and before dust and water resistance certifications.

[0003] Existing methods for detecting leaks to certify the dust and water resistance of a chassis face various challenges. For example, leak detection is time-consuming because it takes time for the chassis to dry after being immersed in water. On the other hand, airtightness testing is expensive because gas is filled into the chassis or the chassis is evacuated to stabilize the pressure inside the chassis, thus requiring strict control of air pressure and flow rate. Therefore, there is a need for an accurate, efficient, and inexpensive detection method to detect leaks in a chassis in a production environment. Summary of the Invention

[0004] The terms embodiments and like terms, such as implementations, configurations, aspects, examples, and selections, are intended to refer generically to all subject matter of the present invention and the appended claims. Statements containing these terms should be understood not to limit the subject matter described herein or the meaning or scope of the following claims. The embodiments of the present invention covered herein are defined by the following claims rather than by the summary of the invention. The summary of the invention is a high-level overview of various aspects of the present invention and introduces some concepts that will be further described in the following detailed description section. The summary of the invention is not intended to identify the key or essential features of the claimed subject matter. The claimed subject matter should be understood by reference to the appropriate portions of the entire specification of the present invention, any or all of the drawings, and each claim.

[0005] According to certain aspects of the present invention, a method for detecting leakage of a chassis is disclosed. The method includes mounting the chassis on a plate on a sealed chamber, and fluidly connecting the interior space of the sealed chamber to a water tank through a pipe such that the bottom end of the pipe is below the water level in the water tank. The method further includes determining whether bubbles are formed at the bottom end of the pipe due to pressurized air flowing into the pipe. The method also includes determining the presence of a leak in the chassis due to the pressurized air flowing between the chassis and the sealed chamber before flowing into the pipe.

[0006] According to certain aspects of the present invention, the bubbles are observed through a window on the outer surface of the water tank.

[0007] According to certain aspects of the present invention, the chassis is a part of outdoor electronic equipment.

[0008] According to certain aspects of the present invention, the pressurized air has a pressure between about 10 kiloPascals (kPa) and about 20,000 kPa.

[0009] According to certain aspects of the present invention, the pressurized air is applied for a period of time between about 10 seconds and about 180 seconds.

[0010] According to certain aspects of the present invention, the chassis is sealably covered by a lid. In these aspects, the method further includes using a conduit through the lid to supply the pressurized air to the chassis. In these aspects, the presence of a leak in the chassis is confirmed based on the pressurized air flowing from the chassis to the sealed chamber.

[0011] According to certain aspects of the present invention, the chassis is not sealably covered by a lid. In these aspects, the method further includes directly supplying the pressurized air to the sealed chamber. In these aspects, the presence of a leak in the chassis is confirmed based on the pressurized air flowing from the sealed chamber to the chassis. In these aspects, the chassis is mounted on the plate by a transfer plate coupled to the plate, and the chassis is sealably mounted on the transfer plate.

[0012] According to certain aspects of the present invention, a system for detecting leakage of a chassis is disclosed. The system includes a sealed chamber, a plate disposed on the sealed chamber, an air tube fluidly connected to the sealed chamber, and a water tank. The plate is for mounting the chassis. The air tube is configured to deliver pressurized air into the interior space of the sealed chamber. The water tank is fluidly connected to the sealed chamber through a pipe such that the bottom end of the pipe is below the water level in the water tank.

[0013] In certain aspects of the present invention, the system further includes a window located on the outer surface of the water tank for observing whether bubbles are formed at the bottom end of the pipeline.

[0014] In certain aspects of the present invention, the plate separates the sealed chamber and the water tank.

[0015] In certain aspects of the present invention, when the chassis is not hermetically covered by the cover, the system further includes an adapter plate that couples to the plate to hermetically mount the chassis.

[0016] In certain aspects of the present invention, the system further includes a compressor coupled to the air pipe for delivering pressurized air having a pressure between about 10 kPa and about 20,000 kPa.

[0017] In certain aspects of the present invention, the system further includes a pressure meter coupled to the air pipe for detecting the pressure of the pressurized air delivered to the sealed chamber.

[0018] In certain aspects of the present invention, when the chassis is hermetically covered by the cover, the system further includes a conduit that fluidly connects the air pipe to the interior space of the chassis through the cover.

[0019] The above summary of the invention does not cover every embodiment or every aspect of the present invention. Rather, the foregoing summary merely provides examples of some of the novel aspects and features described herein. Through the following detailed description of various representative embodiments and methods of practicing the present invention, in conjunction with multiple drawings and the appended claims, the above features and benefits, as well as other features and benefits of the present invention, will be readily apparent. Given the detailed description of the various embodiments, in conjunction with the drawings and the following brief description of the drawings provided, those of ordinary skill in the art will understand additional aspects of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present invention and its benefits and the drawings will be better understood through the following description of various representative embodiments and with reference to the drawings. These drawings only depict various representative embodiments and should not be considered as limiting the scope of the various embodiments or the claims.

[0021] Figure 1A A schematic side view of a system for detecting leaks in a chassis not hermetically covered by a cover according to some aspects of the present invention;

[0022] Figure 1B A perspective view of a chassis not hermetically covered by a cover and tested with the system according to some aspects of the present invention; Figure 1A of the system;

[0023] Figure 2ASchematic side view of a system for detecting leakage of a chassis sealed by a cover for some aspects of the present invention;

[0024] Figure 2B For some aspects of the present invention, the chassis is sealed by a cover and tested with a Figure 2A system; and

[0025] Figure 3 For some aspects of the present invention, a method block diagram for detecting Figure 1B and Figure 2B chassis leakage.

[0026] The present invention can be applied in various different variations and alternative forms; some representative embodiments have been shown by way of example in multiple figures and will be described in detail herein. However, it should be understood that the present invention is not limited to the specific forms disclosed. Rather, the present invention encompasses all variations, equivalents, and alternatives falling within the spirit and scope of the present invention.

[0027] Symbol description

[0028] 100, 200: System

[0029] 110, 210: Sealed chamber

[0030] 120, 220: Air pipe

[0031] 122, 222: Compressor

[0032] 124, 224: Pressure gauge

[0033] 130, 230: Plate

[0034] 135: Fastener

[0035] 140, 240: Water tank

[0036] 145, 245: Water surface

[0037] 150, 250: Chassis

[0038] 151: Outer surface

[0039] 152, 252: Bottom plate

[0040] 153: Inner surface

[0041] 154a, 154b, 154c, 154d, 254a, 254b, 254c, 254d: Wall panel

[0042] 156a, 156b, 156c, 156d, 256a, 256b, 256c, 256d: Outer surface

[0043] 158a, 158b, 158c, 158d, 258a, 258b, 258c, 258d: Inner surface

[0044] 160, 260: Window

[0045] 170, 270: Pipe

[0046] 172, 272: Top end

[0047] 174, 274: Bottom end

[0048] 180: Adapter plate

[0049] 182: Lower step

[0050] 184: Upper step

[0051] 185: Sealing member

[0052] 186: Fastener

[0053] 188: Pore

[0054] 253: Knob

[0055] 255: Cover

[0056] 257p, 257q, 257r, 257s: Fastener

[0057] 280: Conduit

[0058] 282, 284: Joint

[0059] 285: O-ring

[0060] 300: Method

[0061] 310, 320, 330, 340: Block Detailed implementation manner

[0062] Multiple embodiments of the present invention are directed to a system and method for detecting leaks in a chassis. The system and method described herein can easily detect leaks in the chassis by determining, for example, by visual observation, whether there are bubbles in the water in a water tank that is fluidly connected to a sealed chamber in which the chassis is placed. The presence of bubbles confirms that pressurized air has leaked from the chassis into the sealed chamber, without the need to immerse the chassis in the water in the water tank.

[0063] Various embodiments are described with reference to the accompanying drawings, in which like reference numerals are used for like or equivalent elements in the various drawings. The drawings are not necessarily to scale and are provided only to illustrate aspects and features of the present invention. Many specific details, relationships, and methods are set forth to provide a thorough understanding of certain aspects and features of the present invention, but those of ordinary skill in the relevant art will understand that these aspects and features may be practiced without one or more of the specific details, or may be practiced with other relationships or other methods. In some cases, well-known structures or operations are not shown in detail for purposes of illustration. The various embodiments disclosed herein are not necessarily limited to the order of the actions or events described, as some actions may occur in a different order and / or concurrently with other actions or events. In addition, not all of the described actions or events are necessary to implement certain aspects and features of the present invention.

[0064] For the purposes of this embodiment, unless specifically stated and where appropriate, the singular form includes the plural form and vice versa. The word "comprising" means "including but not limited to". In addition, words indicating approximate estimation, such as "about", "almost", "substantially", "approximately", etc., may be used herein, for example, to mean "at this value", "close to this value", or "almost at this value", or "within 3 - 5% of this value", or "within the allowable manufacturing tolerance", or any logical combination thereof. Similarly, the words "vertical" or "horizontal" respectively additionally include within 3 - 5% of the vertical or horizontal direction. In addition, words describing directions, such as "top", "bottom", "left", "right", "above", and "below", refer to the equivalent directions described in the reference drawings; as understood from the context of the object or element being referred to, for example, from the normal position of the object or element; or as described herein.

[0065] Figure 1A A schematic side view showing a system for detecting leakage of a chassis that is not hermetically sealed by a lid. The chassis 150 is a part that cannot seal itself with a single component. Figure 1B A perspective view of the chassis 150 is shown. The chassis 150 can be made of metal or alloy to house mechanical and electrical parts therein. In some embodiments, the chassis 150 is a part of an outdoor electrical device. As Figures 1A to 1B shown, the chassis 150 has a bottom plate 152 surrounded by four side walls 154a, 154b, 154c, and 154d. The bottom plate 152 has an outer surface 151 and an inner surface 153. Each of the four side walls 154a, 154b, 154c, and 154d has an outer surface 156a, 156b, 156c, and 156d and an inner surface 158a, 158b, 158c, and 158d. The chassis 150 is tested for leakage within the system 100.

[0066] System 100 includes a sealed chamber 110 and a plate member 130. The plate member 130 is disposed on the sealed chamber 110 to mount a chassis 150. The sealed chamber 110 is assembled to prevent air from flowing into the sealed chamber 110 in a manner other than through the air pipe 120 and the conduit 170. The air pipe 120 is fluidly coupled to a compressor 122 outside the sealed chamber 110 to deliver pressurized air to the internal space of the sealed chamber 110. A pressure gauge 124 is coupled to the air pipe 120 to detect the pressure of the pressurized air delivered to the sealed chamber 110 and display the measured pressure value.

[0067] A water tank 140 is disposed below the sealed chamber 110. Water is injected into the water tank 140 to form a water surface 145. The plate member 130 separates the sealed chamber 110 and the water tank 140. The water tank 140 is fluidly connected to the sealed chamber 110 through a conduit 170 of the plate member 130, enabling air to flow between the sealed chamber 110 and the water in the water tank 140 through the conduit 170. The conduit 170 has a top end 172 and a bottom end 174. The top end 172 leads to the sealed chamber 110, and the bottom end 174 is located below the water surface 145 in the water tank 140. In some embodiments, for example Figure 1A in the illustrated embodiment, the water tank 140 has a window 160 on its outer surface for observing the water surface 145 in the water tank 140 and for observing whether bubbles form at the bottom end 174 of the conduit 170.

[0068] In some embodiments, a transfer plate 180 is coupled to the plate member 130 to mount the chassis 150 sealingly within the sealed chamber 110. In some embodiments, for example Figure 1A in the illustrated embodiment, the transfer plate 180 has a stepped configuration, where the lower step 182 is coupled to the plate member 130 by a fastener 135, and the upper step 184 is sealingly coupled to the chassis 150 along four wall panels 154a, 154b, 154c, 154d (154a, 154c are shown in Figure 1B ) by a sealing member 185 and fasteners 186. The sealing member is, for example, an O-ring. The transfer plate 180 has an aperture 188 that enables air to flow between the chassis 150 and the conduit 170. In other embodiments, the chassis 150 can be directly mounted on the plate member 130 and sealingly coupled to the plate member 130 using an O-ring (not shown)

[0069] During operation, once the chassis 150 is mounted on the plate 130 of the sealed chamber 110, whether directly or through the adapter plate 180, the sealed chamber 110 will be closed. The compressor 122 operates to deliver pressurized air into the sealed chamber 110, and a pressure gauge 124 is used to detect the pressure of the pressurized air. The delivered pressurized air generally has a pressure between about 10 kPa and about 20,000 kPa and is maintained for about 10 seconds to 3 minutes. If there is a leakage hole in the chassis 150, the pressurized air from the sealed chamber 110 will enter the chassis 150 through the leakage hole and flow into the water in the water tank 140 through the pores 188 in the adapter plate 180. Any leakage present in the chassis 150 can be revealed by bubbles at the bottom end 174 of the pipe 170 formed below the water surface 145 in the water tank 140.

[0070] Figure 2A Schematic side view showing a system for detecting leakage of a chassis covered hermetically by a cover. Figure 2B Perspective view showing the chassis 250. The chassis 250 can be made of metal or alloy to house mechanical and electrical parts therein. In some embodiments, the chassis 250 is a part of an outdoor electrical device. As Figures 2A to 2B shown, the chassis 250 has a bottom plate 252 surrounded by four side walls 254a, 254b, 254c, 254d. The chassis 250 is hermetically covered by a cover 255. Each of the four side walls 254a, 254b, 254c, 254d has an outer surface 256a, 256b, 256c, 256d and an inner surface 258a, 258b, 258c, 258d. The cover 255 is hermetically coupled along the edges of the four side walls 254a, 254b, 254c, 254d, and the cover 255 and these side walls are interconnected by corner fasteners 257p, 257q, 257r, 257s. The cover 255 has a knob 253 for moving the cover 255. The chassis 250 is tested for leakage within the system 200.

[0071] The system 200 includes a sealed chamber 210 and a plate 230, and the plate 230 is disposed on the sealed chamber 210 to mount the chassis 250. The sealed chamber 210 is assembled to prevent air from flowing into the sealed chamber 210 in a way other than through the air pipe 220 and the pipe 270. The air pipe 220 is fluid-coupled to a compressor 222 outside the sealed chamber 210 to deliver pressurized air into the internal space of the chassis 250 in the sealed chamber 210 through the cover 255. A pressure gauge 224 is coupled to the air pipe 220 to detect the pressure of the pressurized air delivered to the sealed chamber 210 and display the measured pressure value.

[0072] The conduit 280 fluidly connects the trachea 220 to the interior space of the chassis 250 through the cover 255. The conduit 280 has a fitting 282 at the connection between the conduit 280 and the cover 255, and a fitting 284 at the connection between the conduit 280 and the trachea 220. The fittings 282, 284 can be made of metal or plastic materials. The cover 255 is sealingly coupled to the chassis 250 through an O-ring 285.

[0073] The water tank 240 is disposed below the sealed chamber 210. Water is injected into the water tank 240 to form a water level 245. The plate member 230 separates the sealed chamber 210 and the water tank 240. The water tank 240 is fluidly connected to the sealed chamber 210 through a conduit 270 of the plate member 230, so that air can flow between the sealed chamber 210 and the water in the water tank 240 through the conduit 270. The conduit 270 has a top end 272 and a bottom end 274. The top end 272 leads to the sealed chamber 210, and the bottom end 274 is located below the water level 245 in the water tank 240. In some embodiments, such as Figure 2A the illustrated embodiment, the water tank 240 has a window 260 on the outer surface for observing the water level 245 in the water tank 240 and for observing whether bubbles are formed at the bottom end 274 of the conduit 270. In other embodiments, the water tank 240 may have a transparent outer wall for observing the water level 245 in the water tank 240 and for observing whether bubbles are formed at the bottom end 274 of the conduit 270.

[0074] During operation, once the chassis 250 is mounted on the plate member 230 on the sealed chamber 210, the sealed chamber 210 is closed. The compressor 222 operates to deliver pressurized air into the sealed chamber 210, and a pressure gauge 224 is used to detect the pressure of the pressurized air. The delivered pressurized air generally has a pressure between about 10 kPa and about 20,000 kPa and is maintained for about 10 seconds to 3 minutes. If there is a leak hole in the chassis 250, the pressurized air from the chassis 250 will enter the sealed chamber 210 through the leak hole and be discharged into the water in the water tank 240 through the conduit 270. Any leak present in the chassis 250 can be revealed by bubbles formed at the bottom end 274 of the conduit 270 below the water level 245 in the water tank 240.

[0075] Figure 3 Illustrating detection Figure 1B And Figure 2B a block diagram of a method 300 for detecting chassis leakage. The method 300 begins at block 310, where the chassis is mounted on a plate member that is disposed in a sealed chamber. The chassis is a part of an outdoor electrical device and may be sealingly covered by a cover or may not be sealingly covered by a cover. As described above and as Figure 1B illustrated, if the chassis is not sealingly covered by a cover, the chassis can be sealingly mounted in the sealed chamber through an adapter plate that is coupled to the plate member.

[0076] In block 320, the internal space of the sealed chamber is fluidly connected to the water tank through a pipe such that the bottom end of the pipe is below the water level in the water tank.

[0077] In block 330, the operator determines whether bubbles are formed at the bottom end of the pipe due to the inflow of pressurized air into the pipe. According to one example, the operator makes the determination by visually observing any formed bubbles. As described above and as Figure 1B associated with Figure 2B shown, an air pipe coupled to a compressor outside the sealed chamber can be used to convey the pressurized air into the sealed chamber. The pressurized air can have a pressure between about 10 kPa and about 20,000 kPa, and the application time is between about 10 seconds and 180 seconds. If the chassis is not hermetically covered by the cover, the pressurized air is directly conveyed into the sealed chamber (see Figure 1B ). If the chassis is hermetically covered by the cover, the pressurized air is conveyed into the chassis using a conduit through the cover (see Figure 2B ). As described above, the bubbles can be observed through a window on the outer surface of the water tank or a transparent wall of the water tank.

[0078] Finally, in block 340, due to the flow of the pressurized air between the chassis and the sealed chamber before flowing into the pipe, the leakage present in the chassis is confirmed. If the chassis is not hermetically covered by the cover, the leakage present in the chassis is confirmed based on the flow of the pressurized air from the sealed chamber to the chassis and through the pipe into the water tank. If the chassis is hermetically covered by the cover, the leakage present in the chassis is confirmed based on the flow of the pressurized air from the chassis to the sealed chamber and through the pipe into the water tank.

[0079] The benefits of the present invention are that the systems and methods described herein provide an accurate, efficient, and inexpensive way to detect leaks in the chassis during the production process and before dust and water resistance certifications. The systems and methods provided by the present invention do not require immersing the chassis in water for a period of time under specified pressure conditions and then drying the chassis. The systems and methods provided by the present invention also do not require obtaining expensive equipment to meet the strict requirements for air pressure and flow control in airtight testing. Therefore, the systems and methods described herein can easily and quickly perform leak detection on a large number of chassis for electrical equipment.

[0080] Although the disclosed embodiments have been described and illustrated with reference to one or more embodiments, those skilled in the art can make equivalent changes and modifications after reading and understanding this specification and the accompanying drawings. In addition, although a particular feature of the present invention may be disclosed in only one of several embodiments, this feature can be combined with one or more other features of other embodiments as needed, and can be beneficial for any particular or specific application.

[0081] Although several embodiments of the present invention have been described above, it should be understood that they are for illustrative purposes only and not limitations of the present invention. Without departing from the spirit or scope of the present invention, many variations of the disclosed embodiments can be made in accordance with the disclosure herein. Thus, the breadth and scope of the present invention should not be limited by any of the above-described embodiments. Rather, the scope of the present invention should be defined in accordance with the appended claims and their equivalents.

Claims

1. A system for detecting leakage of a chassis, comprising: A sealed chamber; A plate member disposed on the sealed chamber, the plate member for mounting the chassis; An air pipe fluidly connected to the sealed chamber, the air pipe configured to convey pressurized air into the inner space of the sealed chamber; And A water tank fluidly connected to the sealed chamber through a pipe such that the bottom end of the pipe is below the water surface in the water tank, Wherein when the chassis is not hermetically covered by a cover, the system further includes an adapter plate that couples to the plate member to hermetically mount the chassis.

2. The system according to claim 1, further comprising a window located on the outer surface of the water tank.

3. The system according to claim 1, wherein the plate member separates the sealed chamber and the water tank.

4. The system according to claim 1, further comprising a compressor coupled to the air pipe, the compressor for conveying pressurized air between 10 kPa and 20000 kPa.

5. The system according to claim 1, further comprising a pressure gauge coupled to the air pipe, the pressure gauge for detecting the pressure of the pressurized air conveyed to the sealed chamber.

6. The system according to claim 1, wherein when the chassis is hermetically covered by a cover, the system further includes a conduit that fluidly connects the air pipe to the inner space of the chassis through the cover.

7. The system according to claim 1, wherein the chassis is a part of an outdoor electrical device.

8. A method for detecting leakage of a chassis using the system according to any one of claims 1-7, comprising: Mounting the chassis on a plate member, wherein the plate member is disposed on a sealed chamber; Fluidly connecting the inner space of the sealed chamber to a water tank through a pipe such that the bottom end of the pipe is below the water surface in the water tank; Determining whether there are bubbles formed at the bottom end of the pipe due to the inflow of pressurized air into the pipe; and Determining the presence of leakage in the chassis.

9. The method according to claim 8, wherein the bubbles are observed through the window of the water tank.

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