Inline Flow Testing with Primed Sealing Heads for Workpieces

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing flow testing methods for components with functional orifices are costly, complex, and typically performed offline, leading to inefficiencies in inline production processes due to their large footprint and high complexity, which hinders high production output with a small footprint, low complexity, and low cost.

Innovation Solution

An automated mass production system with a control system that synchronizes the operation of carriers and testing stations, using first and second sealing heads to form a sealed flow path and measure gas flow rates, enabling efficient inline flow testing of workpieces with reduced complexity and increased productivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If flow testing is performed offline in batch processes, then testing accuracy is maintained, but productivity is reduced and production output is limited

Engineering Contradiction:

Improveflow testing accuracyVSAvoidproduction output

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The system performs preliminary actions by pre-positioning sealing heads and pre-establishing sealed flow paths before actual flow measurement begins. This allows the testing station to be fully prepared and ready for immediate measurement, eliminating setup time during batch processing and enabling continuous inline operation without compromising measurement accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements continuous flow testing by maintaining sealed flow paths and continuous gas flow through multiple workpieces simultaneously. The electronic camming coordination ensures that sealing, flow establishment, and measurement operations continue without interruption, transforming discrete batch operations into a continuous inline process that maintains precision while dramatically increasing productivity.

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If flow testing is implemented inline, then productivity increases, but device complexity and footprint increase

Engineering Contradiction:

Improveproduction outputVSAvoidtesting system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The testing station is designed as a universal multi-functional device that can handle multiple workpieces simultaneously through coordinated sealing heads. The same electronic camming system coordinates both the sealing motion and the gas flow control, making the system capable of performing multiple operations (sealing, flow establishment, measurement) with a single integrated device rather than requiring separate specialized equipment for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system replaces complex mechanical synchronization mechanisms with electronic camming and software coordination. Instead of using physical cams, linkages, and timing chains to synchronize multiple sealing heads and gas flow controls, the invention uses electronic controls and programmed sequences to achieve precise coordination, significantly reducing mechanical complexity while maintaining synchronization accuracy for inline operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If complex tools are used for inline flow testing, then productivity increases, but cost and device complexity increase

Engineering Contradiction:

Improveproduction outputVSAvoidsystem cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The system segments the flow testing process into distinct coordinated phases (sealing phase, flow establishment phase, measurement phase) that can be independently controlled and optimized. By dividing the overall process into manageable segments handled by specialized but simple components (sealing heads, gas sources, sensors) coordinated through electronic camming, the system achieves high productivity without requiring single complex expensive tools for each function.

Inventive Principle:

Principle #1Segmentation

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

The system allows for high production output with inline inspection, achieving low complexity and cost while maintaining precise flow testing, thereby improving production efficiency and reducing bottlenecks in manufacturing processes.

Implementation Method 1

engaging the first sealing head with the inlet of the workpiece and the second sealing head with the outlet of the workpiece to form a sealed flow path

Methodology Applied

Scientific EffectSealing:

Implementation Method 2

measuring the resulting flow of gas at the outlet of the orifice. The flow measured at the outlet can be compared to a threshold or expected value in order to identify the presence of cracks, breaks or blockages

Methodology Applied

Scientific EffectFlow measurement:

Data Source

PatentUS11692552B2Flow testing methods and systems

Publication Date: 2023.07.04 ATS CORPORATION

AI summary

Systems and methods of flow testing different workpieces in an automated testing station are described. Each workpiece comprises a flow path from an inlet to an outlet and the automated testing station comprises first and second sealing heads for injecting gas into the inlets of workpieces and collecting gas from the outlets of workpieces. The method includes performing a flow test by moving the flow test heads toward the workpieces while at the same time priming a flow of gas from the first sealing heads to the second sealing heads, prior to engaging the workpiece.