Automated leak testing for high-volume airbag inflator production
A global supplier of automotive safety components needed an operator-free leak testing system for high-volume production of driver-side pyrotechnic airbag inflators. The system needed to accommodate multiple part models and sizes while integrating directly into an automated production line.
In addition to throughput requirements, the customer required the ability to detect both gross and fine leaks without unnecessarily depleting the helium contained within the parts. The application also presented process challenges, including parts arriving hot from upstream manufacturing operations and the need for automated communication with the production line.
Key project requirements included:
LACO engineered a turnkey dual-chamber leak testing station utilizing both helium hard vacuum and vacuum decay test methods. The system incorporated two independent leak test chambers, allowing high throughput while providing flexibility to perform either helium leak testing or vacuum decay testing based on production requirements.
A dual helicopter-style pick-and-place handling system automatically transferred parts from the conveyor into the test chambers and sorted parts after testing. Universal grippers allowed the system to accommodate multiple inflator designs without extensive changeover, while RFID communication enabled automated product tracking throughout the process.
To meet the customer’s leak testing requirements, the system incorporated an innovative gross leak testing approach that minimized helium loss from the parts. An auxiliary pumping system provided the performance and speed necessary for demanding production environments while maintaining reliable test results.
The completed system delivered:
