EV Battery Leak Test System
IGBT Cooler Test Stand
Power semi-conductor coolers are leak tested and gaged at a rate of 128 parts/hour.
- An InterTech M1075 Mass Flow Leak Detector controls the test cycle.
- Coolers are tested to a 0.8 sccm limit at 3.5 bar absolute (51psia).
- Braze delamination (peanut detection) is checked during the test cycle.
- Integrated barcode scanner interfaces with the InterTech M1075 leak detector to track data by serial number.
- Measurement Capabilities: Test R&R meets QS 9000 requirements.
- Temperature compensation over a 10°C range is included.
- Flexibility: Quick-change fixturing capability adapts to short run production schedules.
- Reliability: Proven InterTech leak test instrumentation and fixture designs ensure production efficiencies.
- Connectivity: Instrument EtherNet/IP interface communicates with customer manufacturing network.
Heat Exchanger Gaging & Test System
Heat exchangers are dimensionally measured and leak tested at a rate of 150 parts/hour.
- Four vision cameras:
- Inspect two product locating slots (3.7 mm slots)
- Two hole locations (3.7 mm holes)
- Two fitting locations
- A laser micrometer is used to measure stack height
- Parts are leak tested to a 0.8 sccm accept limit at 3.5 bar absolute (36.25 psig)
- Quick change tooling accommodates four different models
- An InterTech M1075y leak test instrument controls the leak test cycle
- Two fix mounted 2D barcode scanners and one printer are used to print and verify labels
Lidar IP Integrity Test Station
Sensors are leak tested at a rate of 120 pph.to meet IP67 requirements.
- The InterTech M1075 Mass Flow Leak Detector controls the test cycle.
- Components are leak tested to 5 sccm limit at 10 kPa (1.5 psig).
- Low cost, custom tooling is mounted to the InterTech TechPress module.
- Ergonomic design eliminates carpal tunnel syndrome and operator fatigue – common to toggle clamps.
- Over-clamping and under-clamping of customer parts are eliminated.
- Infinitely adjustable height adjustment over the 6” (152 MM) stroke.
- Consistent sealing force against a positive stop.
- IP67 compliance is verified.
- Speed: Mass flow leak detection technology permits the fast and accurate testing of small volume parts.
- EtherNet/IP compliant: test system is integrated into customer’s quality control system to ensure traceability and compliance with ISO requirements.
- User friendly: automated R&R mode facilitates scheduled machine qualification and audit traceability.
- Cost effective: using the M1075 Leak Detector with an InterTech TechPress provides required flexibility to meet R&D and audit requirements.
Electric Vehicle (EV) Battery Cooling System Air Leak & Functional Test Stand
Parts are functionally tested at a rate of 32 PPH
- Upper case and lower body leak tests are simultaneously performed using TWO InterTech M1075-06y mass flow
leak detectors - Hioki model 3159-02 is used for insulation resistance and high voltage tests
- Hioki model RM3544-01 ohm meter is used for measuring resistance
- Vision camera is provided to check presence of (4 to 6) bolts
- Dimensions: 2500 mm (W) x 1500 mm (D) x 1900 mm (H)
- Load Height: 900 mm from the floor (standing operator)
- Safety: Emergency STOP button, Light Curtains, Guarding with doors
- Test Instrumentations: InterTech M1075-06y mass flow leak detectors and Hioki electrical test instruments
- PC: Industrial CPU interface with the plant Dbase (MES) system
- Input Voltage: 380 VAC, 50 Hz, 3 Phase
1. Manual load in proper orientation and START 5.0 seconds
2. Scan 2D code and verify scanned data from plant network Dbase: 5.0 seconds
3. Activate clamps: 2.0 seconds
4. Activate seals: 2.0 seconds
5. Simultaneously perform upper case leak test & lower body leak test 53.0 seconds
6. Perform temperature sensor test (display & record temperature reading): 2.0 seconds
7. Perform heater temperature test (display & record temperature reading): 2.0 seconds
8. Perform insulation resistance test (high voltage terminal & main body): 5.0 seconds
9. Perform insulation resistance test (high voltage terminal & temp sensor): 5.0 seconds
10. Perform insulation resistance test (high voltage terminal & high volt shield): 3.0 seconds
11. Perform high voltage test (high voltage terminal & main body): 3.0 seconds
12. Perform high voltage test (high voltage terminal and temp sensor): 3.0 seconds
13. Perform high voltage test (high voltage terminal & high volt shield): 3.0 seconds
14. Release seals: 2.0 seconds
15. Release clamps: 2.0 seconds
16. Vision inspection (check for presence of bolts): 5.0 seconds
17. Send & verify test results to plant network Dbase(MES): 5.0 seconds
18. Manual unload: 5.0 seconds
Total: 112.0 seconds
ECU Test Station
Electronic Control Units are leak tested to a 1.06 sccm limit at 0.5 bar at a rate of 100 parts per hour.
- Fixturing is designed to meet IPC strain gage and ESD limits.
- The InterTech M1075 Mass Flow Leak Detector controls the test cycle & machine operation (light curtain interface, barcode scanner, etc.).
- Barcode scanning prior to testing enables seamless data tracking.
- IPC compliant.
- Speed: Mass flow leak detection technology permits the fast and accurate testing of small volume parts.
- EtherNet Compliant: Test system is integrated into customer’s quality control system to ensure traceability and compliance with ISO16949 requirements.
- User Friendly: Automated R&R mode facilitates scheduled machine qualification and audit traceability.
- Cost Effective: Using our EV/AV battery leak test system (M1075 Leak Detector) to control all machine functions simplifies wiring and eliminates expensive purchased components including a PLC.
Consult Our Experts
Please contact InterTech for further information or help with your test application. We are happy to answer any questions you may have. Give us a call at 847-679-3377 or fill out the form and we'll be in touch as soon as possible.
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