In the power system and chassis structure of new energy and fuel vehicles, water-cooled die casting is the preferred process for key components.However, its complex internal flow channels also make“invisible micro leaks”It has become the hardest nut to crack in quality control.
Once the water-cooling cavity or channel leaks, it may cause overheating of core components and performance degradation, or cause circuit short circuits, corrosion of peripheral parts, or even vehicle breakdown or spontaneous combustion, which directly threatens driving safety and brand reputation.
Therefore, whether micro-leakage can be eliminated before mass production has become a must-answer question for both OEMs and parts companies.
This article will take the helium testing test case of automotive water-cooled die castings as an entry point to help you understand how Hirays creates a high-efficiency and high-reliability sealing testing solution for customers, transforms stringent sealing requirements into engineering practices that can be implemented and mass-produced, and protects product quality and brand reputation.
Customer demands: high precision and efficiency
Test parts: water-cooled cavity and internal channels
Test pressure:0.25 MPa – 0.6 MPa
Testing method: Helium testing vacuum box method, testing two products in one chamber
Leak rate threshold:≤ 5×10⁻⁷ Pa·m³/s
compatibility:There are many types of products and they need to be compatible3different states
Test beat:60Test two products in seconds
In order to meet the above requirements, the plan must not only“It can be detected, it can be detected accurately”, more importantly“Quick inspection and easy model change”, and can be seamlessly integrated into the production line.
Solution: Vacuum Chamber Helium Detection System
Hai Ruisi has deployed a set ofHMA series of helium mass spectrometer leak detectors are the core of the vacuum box-type helium detection system. The core composition is as follows:
Core instrument: HM-410 helium mass spectrometer leak detector
Detection system: testing system, filling and recovery system, vacuum system
Vacuum box: customized sealed cavity to adapt to different product states
Fixture system: 3 sets of special fixtures that can be quickly changed
Four steps of testing process
Vacuuming:Put the workpiece into the vacuum box and evacuate the box to prepare for leak detection.
Detecting major leaks:Inject high-pressure nitrogen into the workpiece, and quickly screen for obvious large leaks and structural defects through pressure changes.
Precise detection of micro leaks:After the nitrogen is discharged, the vacuum is precisely evacuated again, and then helium is filled into the workpiece. A helium mass spectrometer leak detector accurately identifies medium and micro leaks.
Recycling helium:After the test is completed, the system automatically recovers the helium in the workpiece to achieve recycling and reduce costs.
Solution advantages: Comprehensive matching of customer needs
This solution perfectly matches the customer’s core demands in terms of accuracy, efficiency, compatibility and cost:
1 Stable performance and accurate detection
The minimum detectable leak rate is 5.0×10⁻¹³ Pa·m³/s, far more than customers5×10⁻⁷ Pa·m³/s According to the requirements, the optimally designed mass spectrometry system and algorithm have fast response and strong anti-interference ability.
2 Adapt to complex structures
The helium inspection vacuum box method can effectively deal with the complex structure of multiple flow channels and multiple welds inside water-cooled die castings, ensuring no dead ends in inspection.
3. Meet the production line rhythm
By optimizing the process and equipment coordination, the inspection rhythm of the two pieces is controlled within60Within seconds, customers’ mass production efficiency requirements can be fully met.
4 Test results are quantified and traceable
The system automatically records the leak rate value of each product, supports data export and statistical analysis, and provides data support for continuous quality improvement.
5 High compatibility and ease of use
Adopting a modular design, product models can be quickly switched by changing the fixture without re-debugging the equipment.
6 Automatic identification to prevent errors and improve efficiency
After the test is completed, the system automatically completes the processing in the vacuum box based on the results: qualified parts are automatically marked, and unqualified parts are not processed, effectively preventing mixing of materials and reducing manual marking and re-inspection.
Hirays Technology
Customer value: higher efficiency, better quality
By deploying this helium detection system, the customer has achieved“Passive leak prevention”arrive“Active leakage control”With the upgrade, quality and efficiency have been comprehensively improved. The specific value is reflected in:
Seamless integration of production lines:The inspection rhythm completely matches the production line, without additional manual intervention.
Flexible production capacity:The quick changeover design can easily cope with multi-category and batch production needs.
Full quality traceability:The data recording and traceability function provides a powerful tool for quality management and problem tracing.
Significant cost reduction:Highly sensitive detection reduces after-sales risks and waste losses, and the modular solution also reduces comprehensive usage costs.
Comprehensive improvement in efficiency:Automated inspection frees up manpower, allowing production lines to focus on core production tasks.
about Us
Hirays is deeply involved in the field of sealing testing18Years of service to customers5000family, which has accumulated thousands of mature application cases, coveringNew energy, liquid cooling, automobiles,3CConsumer electronics, smart wearablesand participated in the drafting and revision of many industry and national standards.
Relying on its profound technological accumulation, Hiraysi's solutions have won the long-term trust of leading companies in many industries.
If you have sealing testing needs for die castings, liquid cooling components, new energy power batteries, motor electronic controls, housing components, etc., please feel free to call or leave a message for consultation.Hiraysi will provide you with professional customized solutions to protect product quality and brand reputation.
