Helium Leak Detection System Parallel Filling and Testing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing leak detection systems face inefficiencies in cycle time due to the time-consuming helium-filling operation, especially when testing multiple hermetically sealed vessels, leading to prolonged leak test cycles.
Innovation Solution
A leak detection system that separates the helium-filling and leak testing operations, utilizing a transfer and carrying mechanism to efficiently move test pieces between filling and detection positions, and employs a guide pipe to direct helium to a mass spectrometer for immediate detection, reducing the time required for the leak test.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the test piece is filled with helium gas using conventional sequential operations (gross leak test, evacuation, then helium filling), then the leak detection can be performed, but the cycle time becomes long due to rate-limitation in the helium-filling operation
Solution Approach 1:
The system divides the leak detection process into two independent parallel segments: (1) helium filling segment performed in the filling-operation position, and (2) leak detection segment performed in the detection position. This segmentation allows both operations to occur simultaneously without interfering with each other, thereby reducing the overall cycle time while maintaining detection precision.
Solution Approach 2:
The system performs the helium filling operation in advance in the filling-operation position before the actual leak detection begins. By preparing the test piece with helium gas beforehand and transferring it to the detection position, the system eliminates the waiting time that would otherwise be required to complete filling during the detection process, thus reducing cycle time without compromising detection accuracy.
2Productivity
If multiple test pieces are subjected to leak tests in succession using conventional methods, then all pieces can be inspected, but the cycle time is prolonged due to sequential processing
Solution Approach 1:
The system maintains continuous useful action by enabling parallel processing: while one test piece undergoes leak detection in the detection position, another test piece simultaneously undergoes helium filling in the filling-operation position. This continuous parallel operation allows multiple test pieces to be inspected in succession without idle time, thereby increasing productivity without extending the cycle time.
Solution Approach 2:
The system segments the inspection process into independent parallel streams that can handle multiple test pieces simultaneously. By having separate filling and detection positions that operate independently, the system can process multiple test pieces through different stages of the workflow at the same time, improving throughput while maintaining the same cycle time per piece.
3Device complexity
If the helium-filling operation is performed inside the test chamber, then the process can be simplified, but the leak detection sensitivity is reduced due to contamination of the vacuum atmosphere
Solution Approach 1:
The system segments the filling and detection operations into separate spatial locations: the filling-operation position is separated from the detection position (test chamber). This spatial segmentation prevents helium gas used for filling from contaminating the vacuum atmosphere in the detection chamber, thereby maintaining high leak detection sensitivity while keeping the overall process relatively simple through dedicated functional zones.
Solution Approach 2:
The system introduces an intermediary transfer mechanism (transfer means) that moves the test piece between the filling-operation position and the detection position. This intermediary allows the filling operation to occur outside the test chamber without directly contaminating the vacuum atmosphere, while still enabling the test piece to be inspected with high sensitivity. The transfer means acts as a mediator that decouples the filling and detection environments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration allows for simultaneous helium filling and leak testing of multiple test pieces without prolonging the cycle time, reducing the overall time needed for leak detection and enhancing efficiency by minimizing the number of parts and optimizing the filling and testing process.
Implementation Method 1
The mass spectrometer is provided with a mass analyzing means for ionizing the gas molecules in the vacuum; and to select only the helium ions
Implementation Method 2
the test chamber is evacuated by the vacuum pump to a predetermined pressure
Data Source
AI summary
A leak detection system has: a test chamber connected to a vacuum pump; a filling device for filling a test piece with helium gas; a transfer device for transferring the test piece between a ready-for-detection position in which the test piece is ready to be carried into the test chamber and a filling-operation position in which the operation of filling helium gas by the filling device is performed; a carrying device for carrying the test piece from the ready-for-detection position to a detection position inside the test chamber; a sealing device for hermetically sealing the test chamber in a state in which the helium-gas-filled test piece is in the detection position; and a leak detector for detecting helium to be leaked out of the test piece when, after having sealed the test chamber by the sealing device, the test chamber is evacuated by the vacuum pump to a predetermined pressure.