The document provides protocols for different types of leak tests on counterparts. It describes the steps to perform a simple leak test using a Festo switch by adjusting air pressure until the switch signals OK, then testing for leaks by introducing a metal rod to break the seal. It also details protocols for simple and complex digital leak tests using a digital switch and electronic plate to control pressure and test timing. Finally, vacuum leak test procedures are outlined using a digital switch and vacuum pump to create negative pressure and check for leaks. Examples of incorrect samples received from customers are also listed, along with notes that the counterpart rather than sample is tested in quality checks.
The document provides protocols for different types of leak tests on counterparts. It describes the steps to perform a simple leak test using a Festo switch by adjusting air pressure until the switch signals OK, then testing for leaks by introducing a metal rod to break the seal. It also details protocols for simple and complex digital leak tests using a digital switch and electronic plate to control pressure and test timing. Finally, vacuum leak test procedures are outlined using a digital switch and vacuum pump to create negative pressure and check for leaks. Examples of incorrect samples received from customers are also listed, along with notes that the counterpart rather than sample is tested in quality checks.
The document provides protocols for different types of leak tests on counterparts. It describes the steps to perform a simple leak test using a Festo switch by adjusting air pressure until the switch signals OK, then testing for leaks by introducing a metal rod to break the seal. It also details protocols for simple and complex digital leak tests using a digital switch and electronic plate to control pressure and test timing. Finally, vacuum leak test procedures are outlined using a digital switch and vacuum pump to create negative pressure and check for leaks. Examples of incorrect samples received from customers are also listed, along with notes that the counterpart rather than sample is tested in quality checks.
Department City Sheets Date QUALITY Ploiesti 1 - 1 27-01-2012 Author Phone Filename Catalin Chirita 034 101188 QI_12_0002 Ver.1 Participants: Copy to: Copy to:
EMDEP GROUP F08.06.00 Poligono Industrial de Entar 43813 ALIO TARRAGONA SPAIN
Protocol leak test
When a counterpart with leak test simple is tested the following steps need to be verified:
Simple: With Festo switch (or similar). The counterpart is activated with a complete connector and the air (with the air regulator) is adjusted until the switch give signal OK. Further is caused a loss of air in the seal from the terminals (by introducing a thin metal rod) and is verified if the OK signal is lost. At extraction of the metal rod (the seal will be in the correct position) the detection should activate itself. If the cause the leak cant be made in this way is removed a seal and is verified if it disables / enables (at the insertion of the seal back). The pressure set from the air regulator is verified with a digital switch (installed in the test board were are tested the counterparts)
Simple digital: with digital switch The digital switch is set at 0.3 bar
The following steps are almost similar: Activate the counterpart with a complete sealed connector. Adjust the air regulator at 0.5 bar. Test the loss of air
Complex digital: Digital switch + electronic plate The digital switch is adjusted at 0.3 bar and Hysteresis at 0.05 (is the maximum variation that the pressure can have during the test) Adjust the electronic plate for the starting time(+- 1 s) and the duration of test (+-5 s)
The following steps are similar: Activate the counterpart with a complete sealed connector. Adjust the air regulator at 0.7-0.8 bar: it is not necessary to be exact because the electronic plate stops the insertion of the air when inside the cavity are reached the value of 0.3 bar Test the air loss
Vacuum simple: Digital Switch - The vacuum pomp create vacuum in the cavity and the digital switch read this pressure - The digital switch is set at pressure -0.50.
The following steps are almost similar: Activate the counterpart with a complete sealed connector. Adjust the digital switch at -0.5 bar. Test the loss of air
QUALITY INFORMATION
Info Client Standard Neumarkt
Date Filename Side 18-01-2012 Protocol leak test 2 / 2
EMDEP GROUP Poligono Industrial de Entar 43813 ALIO TARRAGONA SPAIN Vacuum complex: digital switch + electronic plate Adjust the air regulator at -0.5 bar Adjust the electronic plate for the test starting time (+- 1 s) and the duration of the test (+-5 s): if in the cavity is reached the value of -0.5 bar then the detection signal will be OK, if the pressure in the cavity will not reach -0.5 bar in the seated time then the signal will be NOK
The following steps are similar: Activate the counterpart with a sealed connector. Test the air loss
Below are some examples when are used the samples from Emdep archives: Case 1: the sample from customer gets damaged during the production process (in most cases) Case 2: the sample received from customer is incomplete (missing wire on cavities; missing strap; spacer; seals etc.)
For Leak test, if sample from customer dose not assure the air leakage (missing wires; seals; incorrect wire) then the counterpart is tested with a correct connector (can be used a connector without wires and with the holes covered by plugs or seals)
NOTE: In the quality department is tested the counterpart, not the sample
In the table below are presented some examples of incorrect/incomplete samples: Picture Problem
Strap position. The position of strap can be as black strap or white strap Missing spacer