Tube Seal Pressure Testing for Inline Leak Detection
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Solution Overview
Problem
Existing methods for leak testing in flexible containers, such as tubes, are unable to perform 100% testing for leakage at full production line speeds exceeding 30 packages per minute, and they often require offline testing or multiple testing arrangements, which are inefficient and costly.
Innovation Solution
A leakage detecting device that includes first and second tube pressure means and first and second seal pressure means, which apply predefined pressure to the tube and seal, respectively, while sensor means measure the pressure change, and an electronic control unit determines if a pressure change has occurred, allowing for real-time detection of leaks without contaminating the production line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional leak testing methods are used, then leakage detection is possible, but testing cannot be performed at full production line speeds exceeding 30 packages per minute
Solution Approach 1:
The testing system is divided into multiple parallel testing arrangements, each capable of testing packages independently. This segmentation allows the system to maintain high production speeds by simultaneously testing multiple packages across different testing stations, resolving the contradiction between testing speed and detection reliability.
Solution Approach 2:
The system performs preliminary sealing quality assessment during the filling process itself, before packages leave the production line. By conducting leak testing in-line at the sealing station, the system eliminates the need for separate offline testing phases, thereby maintaining both high productivity and reliable leak detection.
2Productivity
If multiple parallel testing arrangements are provided to increase testing capacity, then more packages can be tested per unit time, but device complexity increases
Solution Approach 1:
Each parallel testing arrangement is designed as a universal module that can test both sealing quality and package integrity using the same core components. This multi-functionality reduces the need for specialized separate testing systems, thereby increasing testing capacity while controlling overall device complexity through standardized modular units.
3Measurement precision
If high pressure is applied to the tube to test seal quality, then seal integrity can be detected, but substance may escape and contaminate the production line
Solution Approach 1:
A controlled atmosphere system with traceable gas introduction acts as an intermediary between the testing mechanism and the packaged substance. By introducing a controlled gas atmosphere and detecting pressure changes rather than applying direct high pressure, the system can detect seal integrity without causing substance escape or contamination of the production line.
Solution Approach 2:
The system replaces direct mechanical high-pressure application with a pneumatic/atmospheric pressure change method. By substituting the mechanical sealing test with a controlled atmosphere pressure change approach, the system achieves seal quality detection while eliminating the harmful effect of substance spillage that would occur with direct high-pressure mechanical testing.
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, inline leak detection of both the seal and the tube itself, without the risk of substance spillage, allowing for immediate discard of defective products and maintaining production efficiency.
Implementation Method 1
sensor means arranged to measure a signal indicative of the pressure in the tube when the first tube pressure means and the second tube pressure means apply the predefined pressure to the tube
Implementation Method 2
a first tube pressure means and a second tube pressure means arranged to apply a predefined pressure to the tube
Implementation Method 3
a first seal pressure means and a second seal pressure means arranged to be positioned at the seal of the tube before the tube pressure means applies a pressure to the tube
Implementation Method 4
an electronic control unit arranged to determine if a pressure change has occurred in the tube based on input from the sensor means
Data Source
AI summary
A leakage detecting device (1) arranged to detect leakage in a seal (23) of a tube (2), comprising a first tube pressure means (3) and a second tube pressure means (4) arranged to provide a predefined pressure to the tube, detection means arranged to detect a pressure change in the tube after the predefined pressure has been applied to the tube, an electronic control unit arranged to compare an initial applied pressure value to a second pressure value to determine if a pressure change has occurred, and to give a fault signal if a pressure change has occurred, where the leakage detecting device (1) comprises a first seal pressure means (16) and a second seal pressure means (17) arranged to be positioned at the seal (23) of the tube (2) when the seal pressure means (3, 4) applies a pressure to the tube (2).