Leak Test Condition Design for Dead-Zone-Free Evaluation
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Solution Overview
Problem
Existing leak test methods, such as differential pressure based air leak tests and helium leak tests, suffer from a 'dead zone' where leaks cannot be detected, and it is difficult to determine and evaluate test results using the same criteria, leading to inconsistent quality assessments.
Innovation Solution
A method and device that convert differential pressure values and helium leak rates into equivalent standard leak rates, allowing for simultaneous evaluation on a shared scale, ensuring no 'dead zone' exists between test regions and enabling clear quality determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If differential pressure based air leak test and helium leak test are performed separately, then each test can detect its respective leak region, but a dead zone occurs where leaks cannot be detected by either test
Solution Approach 1:
The patent converts both differential pressure values from air leak tests and helium leak rates from helium leak tests into equivalent standard leak rates using predetermined conversion formulas. This parameter transformation allows results from different test methods (air vs. helium, differential pressure vs. leak rate) to be expressed in a common standardized unit, enabling direct comparison and evaluation on the same scale, thereby eliminating dead zones where leaks might escape detection
Solution Approach 2:
The patent introduces equivalent standard leak rate as an intermediary parameter that mediates between the differential pressure measurement system and the helium leak rate measurement system. By converting both test results into this common intermediary parameter, the system achieves unified evaluation criteria without requiring direct integration of the different test methods themselves
2Reliability
If different test methods (air leak test and helium leak test) are used, then broader leak detection capability is achieved, but it becomes difficult to evaluate and compare test results using the same criteria
Solution Approach 1:
The patent transforms measurement results from different test methods into a common parameter (equivalent standard leak rate) using predetermined conversion formulas. This allows qualitative assessment of leak severity across different test methods, enabling consistent evaluation criteria while maintaining the advantages of multiple test approaches
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
Enables accurate and consistent evaluation of leak tests by merging differential pressure and helium leak test results, preventing undetectable regions and providing clear quality thresholds.
Implementation Method 1
the differential pressure of the internal pressure between these capsules is detected by a differential pressure sensor
Implementation Method 2
the helium gas that has entered the inner space of the test piece due to the bombing gradually leaks out, so that this is detected by the helium leak detector
Data Source
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AI summary
A leak test condition design method includes: obtaining an internal volume of a test piece and a remaining internal volume of a test piece capsule with the test piece loaded for a differential pressure based air leak test; determining a test air pressure to be applied into the test piece capsule when the differential pressure based air leak test is performed; determining bombing conditions of a helium leak test; obtaining a differential pressure value between a test piece and a master to be gained when the differential pressure based air leak test is performed under the determined test air pressure being applied and converting into an equivalent standard leak rate to derive a differential pressure conversion value; obtaining a helium leak rate of the test piece to be gained when the helium leak test is performed under the determined bombing conditions and converting into an equivalent standard leak rate to derive a helium leak rate conversion value; and displaying the derived differential pressure conversion value and helium leak rate conversion value on a same graph with the equivalent standard leak rate as a horizontal axis.