Airbag manufacturer requires high-speed leak testing in a compact production footprint
A leading airbag inflator manufacturer approached LACO seeking an automated leak test solution that could verify the integrity of airbag diffuser assemblies while fitting within a limited production footprint of just 30″ x 40″.
The application presented several unique challenges. Airbag inflators contain chemical propellants that can be affected by humidity and environmental contaminants if the diffuser assembly is not properly sealed. Every component therefore required reliable leak testing before moving to the next stage of production.
In addition to meeting leak test requirements, the customer needed an extremely fast production rate. The system would need to achieve a part-to-part cycle time of four seconds or less while accommodating multiple diffuser designs and part sizes.
Key project requirements included:
LACO engineered a fully automated leak test system specifically designed for high-volume airbag inflator manufacturing. Custom leak test chambers were developed to closely match the geometry of each diffuser design, significantly reducing chamber dead volume and allowing the system to reach test conditions more quickly.
The system incorporated automated handling, optimized chamber design, and streamlined test sequencing to maximize throughput while maintaining reliable leak detection performance. By minimizing chamber volume and reducing evacuation times, LACO was able to exceed the customer’s cycle time goal while operating within the required footprint.
The completed system delivered:
