For years, manufacturers have been seeking a process leak detection solution that both quantifies and locates leaks. Cincinnati Test Systems, Inc., a long time player in the leak detection market, has developed the solution. Moreover, the technology fills the “GAP” between the measurement sensitivities of pressure and flow measurement instruments and mass spectrometry. Utilizing an array of proprietary sensors that detects the presence of a tracer gas, the instrumentation can detect and locate leaks as small as .001 scc/sec.
A visual image of the leaking part under test is shown on a monitor along with the leak rate in units of standard flow. “This is the first practical leak detection system that locates, quantifies, and visually shows you the magnitude and location of the leak. Falcon® will fundamentally change the perception of leak detection as a method of separating good parts from bad parts to a true, real time, process control tool with the capability of saving companies thousands of dollars.”, says Chris McCoy, President of CTS. “We’re finding leaks that neither pressure decay, nor flow technologies can touch – essentially independent of the part volume and its temperature.”
Jonathan Fazekas, Research Director at CTS, led a team of a physicist, computer scientist and EE's, in the development effort. “We did this right”, says Fazekas, “We didn’t rush to market until we had a sensor and a controller that were perfect. The sensor has both analog and digital outputs and communicates over a C.A.N. network, allowing for easy assembly into arrays. The Falcon Controller is a sophisticated piece of instrumentation with some truly elegant software algorithms. Combined with the Sentry PCS software, we’ve created a leak test platform that is a cutting edge combination of proven technologies.”
Applications include leak testing all types of welds, metal or plastic, gaskets, O-rings, brazed joints, casting surfaces, etc.
“Our first prototype machine tests a torque converter. We’ve built mass spectrometer machines for the same part. Imagine the customer’s surprise when we demonstrated a solution that not only tested his part faster but showed the operator the actual location of the leak in real time, marked the location of the leak on the part, and fed back information to the welding operation - and for thousands of dollars less!”
- Gary Grebe, Marketing Manager.
“After placing fuel rail, headlight, and fuel cell component machines into service, we are now quoting so many applications, it’s hard to keep up. When you look at a monitor and see your part leaking at a specific location, along with a quantitative readout; well to manufacturers, that’s pretty exciting! The technology shortened the debugging time of the resin applying robots on the headlight assembly line by days. The real time feedback on the fuel rail line to the brazing operation has proven invaluable. Falcon is going to revolutionize the whole industry”
- Greg Popp, Sales Manager.
Cincinnati Test Systems manufactures standard leak test instrumentation and custom designed machines utilizing pressure decay, mass flow, mass spectrometry, ultrasonic, and Falcon Leak Test Systems. The Falcon technology is contending for the product of the year awards from both IEN and FEN magazines.
