A large domestic manufacturer that supplies engines to many mainstream automobile brands, its new generation of turbocharged engines sets unprecedented high standards for the sealing of the cylinder block and cylinder head.

Challenge: The original water inspection and differential pressure methods cannot stably detect micron-level casting defects and assembly leaks, resulting in occasional internal leakage of coolant during bench testing and high repair costs.

Hirays solution: We deployed 2 sets of fully automatic online helium mass spectrometry leak detection systems at key stations in its cylinder block and cylinder head production lines.The system is equipped with automatic sealing plugs and robot loading and unloading, achieving 100% online inspection.

Results and data:

Quality breakthrough: The leak detection threshold was successfully increased by an order of magnitude, and the first-time pass rate of the bench test of the factory engine was increased to 99.8%.

Cost savings: The workload of offline repair work due to leakage problems has been reduced by more than 85%, and the average annual repair cost savings exceeds one million yuan.

Proof of efficiency: The inspection time of a single piece is stable within 25 seconds, which perfectly matches its production rhythm of up to 60JPH (60 pieces per hour).