Sealed Test Chamber for Non-Destructive Cable Bundle Leak Detection
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Solution Overview
Problem
Existing methods for testing the tightness of welded joints in cable bundles are destructive and inefficient, leading to potential damage of the cable bundles and increased costs due to unusable components.
Innovation Solution
A non-destructive testing device comprising a first and second test chamber wall element, an adjustment device, and a cable bushing that allows for air pressure testing within a sealed chamber, ensuring the cable bundle remains intact during the test.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a water bath method with compressed air is used to test welded joint tightness, then leak detection capability is improved, but the cable bundle is damaged due to water penetration
Solution Approach 1:
The patent introduces a test chamber as an intermediary environment that isolates the cable bundle from direct water contact. The chamber allows compressed air testing to be performed while water remains outside the chamber, preventing water penetration into the cable insulation while still enabling leak detection through bubble observation in the water bath surrounding the chamber.
Solution Approach 2:
The testing system is segmented into distinct functional zones: a water-filled test chamber for leak detection, a dry outer region for cable bundle placement, and a sealed interface between them. This segmentation allows the harmful water environment to be separated from the test object, enabling non-destructive testing.
2Reliability
If conventional destructive testing methods are used, then leak detection is achieved, but economic and ecological efficiency deteriorates due to unusable cable bundles
Solution Approach 1:
The sealed test chamber acts as a mediator that enables leak detection without direct water-cable contact. The chamber maintains a controlled environment where compressed air can be applied to detect leaks while preventing water from reaching and damaging the cable insulation, thus preserving cable bundle usability.
Solution Approach 2:
The invention converts the potentially harmful water environment into a beneficial testing medium by containing it within a sealed chamber. The water serves as a visual indicator for leak detection (through bubble formation) while its harmful contact with the cable is prevented by the chamber barrier, transforming a destructive element into a useful testing tool.
3Reliability
If test chamber wall elements are clamped together to form a sealed chamber, then sealing tightness is improved, but device complexity increases due to adjustment mechanisms
Solution Approach 1:
The test chamber wall elements are designed with self-aligning features that automatically ensure proper sealing when clamped together. The structure includes built-in sealing surfaces and positioning elements that guide the wall elements into correct alignment, eliminating the need for complex external adjustment mechanisms while maintaining reliable sealing.
Solution Approach 2:
The patent employs flexible sealing elements such as O-rings or gaskets between the rigid test chamber wall elements. These flexible components conform to the mating surfaces and maintain sealing under varying clamp forces, providing reliable sealing without requiring precision alignment or complex adjustment devices.
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 solution enables efficient and non-destructive testing of welded joints, preserving the functionality of the cable bundles and reducing economic and ecological waste.
Implementation Method 1
apply compressed air to the cables at their free ends
Implementation Method 2
the cables of the cable bundle to be tested form sealing elements for the cable bushing
Implementation Method 3
the test chamber sections are clamped towards one another, thereby forming the test chamber
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a testing device (1), a testing set and a method for testing the sealing tightness of a weld node. The testing device (1) comprises a first test chamber wall element (5) having a first test chamber portion (10), and a second test chamber wall element (6) having a second test chamber portion (14), which correspond to each other in order to form a test chamber (15). By means of an adjustment apparatus (7), the testing device (1) can be adjusted between an insertion position in which the test chamber (15) is open for the insertion or removal of the weld node (2), and a testing position in which the test chamber wall elements (5, 6) are loaded toward each other, as a result of which the test chamber (15) is closed. A pressure testing unit can be fluidically connected to a testing pressure connection point (19) which leads at one end into one of the test chamber portions (10, 14). By means of a cable feed-through (21) corresponding to the cables (3) of the cable bundle (4), the cables (3) can be fixed in the testing position. In the testing position, the test chamber (15) and an environment are fluidically sealed off from each other by means of the cable feed-through (21) when the weld node (2) is disposed in the test chamber (15) and the cables (3) are led out of the test chamber (15) through the cable feed-through (21).