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Leak Testing in the Automotive Industry

Leak Testing in the Automotive Industry

Efficient Leak Testing with Tracer Methods

All over the world governments are Vacuum releasing new regulations to lower emissions and fuel consumption and Helium Sniffing to increase the safety of cars. Hence, many components (5%) Sniffing must be tested to lower and lower Helium leak rates and sometimes even new Accumulation components are added to the vehicle Hydrogen (5%) design for this purpose. Tracer gas Accumulation

leak testing offers very efficient methods to test for small leak rates Decay Testing with high reliabilty and independant Water Bath Testing of or humidity. Also Values in mbarl/s 100 10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-8 10-9 10-10 10-11 10-12 many new technologies like electric Values in sccm 100 10 1 0.1 0.01 0.001 10-4 10-5 10-6 10-7 10-8 10-9 10-10 drive trains and fuel cell propulsion Bubbling rate under 1000 100 10 1 20 no no no no no no no no best conditions bubbles/ bubbles/ bubbles/ second/ seconds/ bubbles bubbles bubbles bubbles bubbles bubbles bubbles bubbles generate new applications for second second second bubble bubble ­efficient leak testing ideally met by Theoretical Range Practical Range tracer gas methods.

SNIFFER METHOD The test component is filled with tracer gas or the operating medium. In case of leaks the tracer gas escapes through the leakage channel and is TRACER GAS detected by a sniffer probe. Probe can be moved manually or automatically via a robot. This method is ideally suited when you need to know the

TRACER GAS exact location of the leakage.

VACUUM METHOD The test component is filled with tracer gas in an evacuated vacuum Leak Testing in the chamber when using the vacuum method. In case of a leak, the tracer VACUUM gas escapes through the leak path and is measured by a leak detector Automotive Industry which is connected to the vacuum chamber. Leak detection systems in

TRACER GAS accordance with the vacuum method are characterized by exceptional measuring sensitivity and extremely short measuring times. Applications for Component Manufacturing and Final Assembly Testing ACCUMULATION METHOD The test component is filled with tracer gas and placed in an accumulation chamber. Tracer gas which escapes through leaks in the chamber is equally distributed throughout the chamber via fans. The leak detector measures the total leakage rate of the test component regardless of the position of the CONCENTRATION TRACER GAS TIME 15 sec. leak. As the test takes place under atmospheric conditions, simple and cost-effective chamber systems can be used. Drivetrain | E-Drivetrain | CNG / LNG Fuel Cell Drive | Fuel System

Fuel H2 Drivetrain Cell Drive H2

Automotive Torque Dual fly EGR Charge-air Automotive Fuel cell Fuel cell stack FC pressure Hydrogen Hydrogen Transmisson Fuel cell plate Component converter wheel cooler intercooler Component housing (assembled) sensor gas line fuel tank Sniffing / Accumulation / Accumulation / Accumulation / Vacuum / (Robotic) Sniffing / Vacuum / Sniffing / Testing method Vacuum Testing method Vacuum Vacuum Accumulation Vacuum Vacuum Vacuum Accumulation Accumulation Accumulation Accumulation

10-2 – ...1 mbarl/s ~ 10-4 mbarl/s -4 -5 -2 4 -2 -4 -4 -5 -4 -5 -4 -5 Typical leak rates 10-4 ... 10-5 mbarl/s 10-4 ... 10-5 mbarl/s ~ 10-3 mbarl/s Typical leak rates 10 ... 10 mbarl/s 10 ... 10 mbarl/s 10 ... 10 mbarl/s 10 ... 10 mbarl/s 10 ... 10 mbarl/s 10 ... 10 mbarl/s 1 sccm ~ 0.01 sccm Recommended LDS3000 AQ LDS3000 AQ XL3000flex Modul1000 LDS3000 LDS3000 Modul1000 Recommended INFICON XL3000flex XL3000flex Protec P3000(XL) LDS3000 AQ Modul1000 LDS3000 AQ LDS3000 AQ LDS3000 LDS3000 AQ LDS3000 AQ LDS3000 INFICON products Protec P3000(XL) Protec P3000(XL) LDS3000 AQ LDS3000 LDS3000 LDS3000 LDS3000 products Sensistor Sentrac

Fuel E 1/1 System Filler Neck

E-Drivetrain Automotive Carbon Fuel tank Fuel tank Tank filler neck Tank filler cap Fuel pump Hoses for Component canister sending unit Automotive Assembled Cell cap Battery case electric battery Electric motor Inter-cell cooler Sniffing / Accumulation / Accumulation / Accumulation / Accumulation / Component battery pack Testing method Vacuum cooling Accumulation Vacuum Vacuum Vacuum Vacuum Vacuum / Vacuum / (Robotic) Sniffing / (Robotic) Sniffing / Vacuum / 10-1 – ...1 mbarl/s ~ 10-4 mbarl/s ~ 10-4 mbarl/s Testing method Sniffing Typical leak rates 10-3 ...10-4 mbarl/s 10-4 ...10-5 mbarl/s ~ 10-3 mbarl/s Bombing Accumulation Accumulation Accumulation Accumulation 5 ... 100 sccm ~ 0.01 sccm ~ 0.01 sccm Typical leak rates 10-6 mbarl/s 10-2 ... 10-4 mbarl/s 10-2 ... 10-4 mbarl/s 10-4... 10-5 mbarl/s 10-3 ... 10-5 mbarl/s 10-3 ... 10-5 mbarl/s Recommended LDS3000 LDS3000 AQ Modul1000 LDS3000 AQ LDS3000 AQ Modul1000 INFICON Modul1000 Recommended LDS3000 AQ LDS3000 AQ LDS3000 LDS3000 LDS3000 LDS3000 LDS3000 Modul1000 LDS3000 XL3000flex LDS3000 Protec P3000(XL) INFICON XL3000flex XL3000flex products LDS3000 LDS3000 AQ Protec P3000(XL) LDS3000 AQ products Protec P3000(XL) Protec P3000(XL)

EV Automotive High pressure High pressure High pressure Fuel pressure Fuel injector Fuel filter Component fuel pump fuel rail fuel line sensor Automotive Battery module Sub-cooled Cooling Lithium-ion Chiller Accumulation / Accumulation / Accumulation / Accumulation / Component cold plate loop radiator pipeline battery cells Testing method Accumulation Vacuum Vacuum Vacuum Vacuum Vacuum Accumulation / Accumulation / Accumulation / Accumulation / Vacuum / Testing method -4 -4 5 -5 -4 5 -2 -4 6 Vacuum Vacuum Vacuum Sniffing Bombing Typical leak rates ~ 10 mbarl/s 10 ...10 mbarl/s ~ 10 mbarl/s 10 ...10 mbarl/s ~ 10 mbarl/s 10 ...10 mbarl/s Recommended Typical leak rates 10-3 – 10-5 mbarl/s 10-4 – 10-5 mbarl/s 10-4 – 10-5 mbarl/s 10-4 – 10-5 mbarl/s ~ 10-6 mbarl/s LDS3000 AQ LDS3000 AQ LDS3000 AQ Modul1000 INFICON LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 LDS3000 LDS3000 LDS3000 Recommended LDS3000 AQ LDS3000 AQ LDS3000 AQ products XL3000flex Modul1000 INFICON LDS3000 LDS3000 LDS3000 Protec P3000(XL) LDS3000 products Modul1000 Modul1000 Modul1000 Sensistor Sentrac

Servo

Automotive Swirl pot DEF (“AdBlue“) Servo oil Component (Diesel) tank housing reservoir reservoir CNG Accumulation / Testing method Accumulation Accumulation Accumulation Accumulation CNG / LNG CNG Vacuum Typical leak rates 10-2 ... 10-4 mbarl/s ~ 10-4 mbarl/s 10-2 ... 10-4 mbarl/s 10-2 ... 10-4 mbarl/s 10-3 ... 10-4 mbarl/s Automotive Natural gas Recommended LDS3000 AQ Component engine tank INFICON LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 products Testing method Sniffing Sniffing ~ 10-4 mbarl/s Typical leak rates 10-4 ... 10-5 mbarl/s ~ 0.01 sccm Recommended XL3000flex XL3000flex INFICON Protec P3000(XL) Protec P3000(XL) products

Product names and components in bold are linked for further information. Product names and components in bold are linked for further information. Safety Features | AC System | Oil and Water Circuit Various | Final Assembly

Safety Features Various

Windshield Automotive Vacuum brake Air suspension Automotive Xenon light Brake hoses Brake calipers Air Air brake tank wiper fluid Wheel rims Starter battery Component pump Component bulbs container Vacuum / Testing method Accumulation Accumulation Vacuum Vacuum Vacuum Testing method Accumulation Vacuum Sniffling Accumulation Accumulation 10-4 ... 10-5 mbarl/s 10-4 ... 10-5 mbarl/s Typical leak rates ~ 10-2 mbarl/s ~ 10-4 mbarl/s ~ 10-6 mbarl/s ~ 10-3 mbarl/s ~ 10-1 mbarl/s Typical leak rates 10-3 ...10-4 mbarl/s 10-3 ...10-4 mbarl/s 0.03 to 0.03 to ~ 10-5 mbarl/s Recommended 5...20 sccm Modul1000 LDS3000 AQ 0.0006 sccm 0.0006 sccm INFICON LDS3000 AQ Ecotec E3000 LDS3000 Sensistor Sentrac Recommended Modul1000 products Modul1000 Modul1000 Modul1000 INFICON LDS3000 AQ LDS3000 AQ LDS3000 LDS3000 LDS3000 LDS3000 products LDS3000 AQ

Final

Automotive Air suspension Shock Seat belt Airbag Airbag Power brake Assembly Fuel Component cylinder absorber pretensioner ignitor caps generator booster Cooling circuit Automotive Engine fuel Fuel rail Testing method Vacuum Vacuum Accumulation Bombing Vacuum Accumulation for drive Component systems circuit connections Cold gas: battery 10-6 ... 10-8 mbarl/s 5 g/a of 5 g/a of refrigerant Typical leak rates ~ 10-5 mbarl/s ~ 10-4 mbarl/s 10-3 ...10-4 mbarl/s ~ 10-4 mbarl/s 10-3 ... 10-4 mbarl/s Typical leak rates 10-3 ...10-5 mbarl/s ~ 10-4 mbarl/s Hot gas: per joint per joint 10-3 ...10-4 mbarl/s Sensistor Sentrac Recommended Recommended XL3000flex HLD6000 HLD6000 Modul1000 Modul1000 Modul1000 LDS3000 AQ INFICON Ecotec E3000 INFICON LDS3000 AQ LDS3000 AQ Protec P3000(XL) Ecotec E3000 Ecotec E3000 LDS3000 LDS3000 LDS3000 LDS3000 products products Ecotec E3000

AC System FRONT AREAS:

Automotive 9 Evaporator Condensor Filling valve Expansion valve AC Hoses Compressor 7 1 Drivetrain Component 8 10 Vacuum / Vacuum / Vacuum / Vacuum / Vacuum / Testing method Accumulation Accumulation Accumulation Accumulation Accumulation Accumulation 2 E-Drivetrain Typical leak rates ~ 10-5 mbarl/s ~ 10-5 mbarl/s ~ 10-5 mbarl/s ~ 10-5 mbarl/s ~ 10-5 mbarl/s ~ 10-5 mbarl/s 1 4 Recommended LDS3000 LDS3000 LDS3000 LDS3000 LDS3000 3 CNG / LNG INFICON LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 AQ products Modul1000 Modul1000 Modul1000 Modul1000 Modul1000 4 Fuel Cell Drive

5 Fuel System Oil & Water REAR 6 Safety Features Pump Circuit 3 5 Automotive Coolant 7 AC System Plastic oil tank Oil cooler Oil pump Water cooler Component expansion tank 6 2 Vacuum / Vacuum / Accumulation / Testing method Accumulation Accumulation 8 Oil & Water Accumulation Accumulation Sniffling 10-2 ... 10-1 mbarl/s 10-2 mbarl/s Typical leak rates ~ 10-1 mbarl/s 10-2 mbarl/s ~ 10-1 mbarl/s 1 ... 10 sccm 1 sccm 9 Various Recommended Modul1000 Sensistor Sentrac INFICON LDS3000 AQ LDS3000 LDS3000 AQ LDS3000 AQ LDS3000 AQ LDS3000 AQ (LDS3000) products 10 Final Assembly

Product names and components in bold are linked for further information. Product names and components in bold are linked for further information. Leak Detectors for Component Pretesting Integral, Automated Testing

LDS3000 SYSTEM LDS3000 AQ MODUL1000 LEAK DETECTOR ACCUMULATION VACUUM LEAK LDS3000 is a modular leak LEAK DETECTOR DETECTOR detector used in integrated LDS3000 AQ is the first leak Modul1000 is a plug and play leak detection chamber detector to use helium or cost leak detector for universal systems. Its compact design efficient forming gas (5 % integration into industrial leak and variety of interfaces and hydrogen in 95 % nitrogen) testing systems (vacuum or protocols allows for easy for simple accumulation leak sniffer mode). With flexible He H2 He H2 He H2 integration into automated detection. The LDS3000 AQ vacuum architecture, the testing systems. An optional is very sensitive and can Modul1000 provides the touch screen display enables detect leaks down to the adaptability to accommodate easy operation. 10-5 mbar∙l/s range. changes in production specifications. Manual and Robotic Sniffing for Leak Localization

PROTEC P3000(XL) SENSISTOR SENTRAC™ XL3000FLEX LEAK DETECTOR LEAK DETECTOR LEAK DETECTOR Protec P3000(XL) is specifically Sensistor Sentrac is a The XL3000flex High Flow designed for full-time sniffing dedicated sniffer leak Technology Leak Detector applications in industrial detector for locating leaks guarantees the highest production environments. in a variety of situations. measuring sensitivity, even The unit allows the operator High selectivity, wide dynamic at longer distances. Leaks to detect gaseous leaks in range and short recovery time can be detected reliably He H2 He H2 even difficult to reach locations make this detecor – which uses regardless of imprecise and is designed to prevent forming gas as a tracer gas – handling and in hard to reach operator errors. highly adaptable. places. The XL3000flex is also ideal for robotic applications.

Leak Detectors for Final Fluid Testing Stop Leaking Profits

HLD6000 REFRIGERANT LEAK DETECTOR ECOTEC E3000 MULTI-GAS LEAK DETECTOR HLD6000 is a sniffer leak detector for testing air condi- Ecotec E3000 allows the operator to detect leaks by INFICON products support both complete part testing and leak location methods so you can stop leaking tioning assemblies. It is available for hydrocarbons as sniffing for the escape of a final medium like fuel or profits. Select from a wide range of test and leak testing products to assure you are using the best well as for CO . Its dual inlet technology guarantees high refrigerant. The unit can detect four gases selectively 2 leak testing technology for your particular application. Our leak detectors provide the highest quality and reliability and repeatability of results, even in environments at any time. Ecotec E3000 is designed to minimize with an increased concentration of refrigerant. operator error and to maximize reliability of testing. increased process safety. Your Reliable Partner from Applications Support to Service He H2 A specially assigned contact person who knows the requirements of your industry will work with you to define the desired specifications. After installation of your new leak detector, we support you with ­world-class service and troubleshooting expertise, if needed, to get the most out of your leak detector. An INFICON leak detector is optimized for its specific leak testing application. Products and services Leak Detectors for Automotive Service are continuously improved in close cooperation with our experts in development. This also includes the evaluation of new leak testing products at the customer’s site. INFICON leak detectors not only are at SERVICE LEAK DETECTORS D-TEK® Select, D-TEK® Stratus and Gas-Mate® are the forefront of technology and offer the highest performance, but are also very easy to operate. With battery operated leak detectors for vehicle air condi- an INFICON leak detector, long training periods or errors in handling are simply a thing of the past. tioning service. The WhisperTM ultrasonic leak detector is a versatile tool useful in detecting worn pistons and bearings as well as door seal leaks.

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SUITABILITY FOR GASES: www.inficon.com [email protected] He Helium H Hydrogen (Forming gas) Refrigerant Fuel Due to our continuing program of product improvements, specifications are subject to change without notice. 2 miba00en-03-(1907) © 2019 INFICON