Custom Solution | FLEXSTATION Leak Test System for Air Brake Actuators

A leading manufacturer of air brake components wanted to migrate from their existing bubble leak test system to a helium leak test system for testing their air brake actuators. The system would require tooling for multiple part models. Additional requirements included:

• Ability to inteface hard tooling with parts with loose dimensional tolerancing
• Simple operator loading process with hard tooling
• Address permeation issues of the actuator bladder
• Option for operator or robot loading
• Option for helium mixing

To meet these requirements, we engineered a helium hard vacuum leak test system integrated with our FLEXSTATION platform. The system incorporates dual custom test chambers with custom tooling designed specifically for air brake actuators, delivering consistent sealing, reliable leak detection, and scalable operation across multiple product configurations.