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泄漏測試的重要性（中英文）

泄漏測試是一種產(chǎn)品質(zhì)量控制方法，通過對(duì)制造部件或系統(tǒng)泄漏進(jìn)行孔隙度測試來識(shí)別制造過程中的不一致性。這種無損檢測通常通過密封測試產(chǎn)品可能存在的任何端口或孔洞，然后將測試介質(zhì)（通常是空氣、氮?dú)饣蚝猓┮霚y試件內(nèi)部或周圍來完成。然后，經(jīng)過培訓(xùn)的操作員或泄漏測試儀器將能夠觀察到產(chǎn)品的任何泄漏。

泄漏測試可以在整個(gè)制造過程的各個(gè)階段進(jìn)行。許多原始設(shè)備制造商 (OEM) 要求在組裝前對(duì)組件進(jìn)行泄漏測試，以確保完整性。OEM 還可能在組裝的不同階段對(duì)整個(gè)系統(tǒng)進(jìn)行泄漏測試，以確保為最終用戶提供最佳、安全的產(chǎn)品。同樣，在產(chǎn)品開發(fā)過程的不同階段，可能會(huì)使用泄漏測試來對(duì)原型進(jìn)行臺(tái)架測試。本文將介紹實(shí)施泄漏測試流程時(shí)的重要注意事項(xiàng)，以及泄漏測試行業(yè)的一些主要趨勢。

Leak testing is a method of product quality control that identifies manufacturing inconsistencies by porosity testing a manufactured part or system leaks. This non-destructive test is typically accomplished by sealing any ports or holes the test product might have and then introducing a test medium—usually air, nitrogen, or helium—into or around the test piece. From there, a trained operator or a leak test instrument will be able to observe any leaks coming into or out of the product.  

A leak test can be performed at various stages throughout the manufacturing process. Many original equipment manufacturers (OEMs) require that components be leak tested to ensure integrity before assembly. The OEM might also perform a leak test on the entire system during different stages of assembly to ensure an optimal, safe product for the end-user. Similarly, a leak test might be used at various times during a product development process to bench test prototypes. Throughout this post, we will cover important considerations when implementing a leak testing process, as well as some key trends in the leak testing industry.  

為何要進(jìn)行泄漏測試？

Why Leak Test?

泄漏測試可驗(yàn)證制造的產(chǎn)品是否符合預(yù)定規(guī)格，從而確保部件或系統(tǒng)能夠按預(yù)期運(yùn)行。此過程對(duì)于確保產(chǎn)品質(zhì)量和最終用戶的安全至關(guān)重要。此外，可靠的泄漏測試流程有助于減少產(chǎn)品保修索賠，并降低系統(tǒng)制造商的質(zhì)量成本。

優(yōu)化泄漏測試流程還能帶來多種生產(chǎn)效率優(yōu)勢。泄漏測試有助于驗(yàn)證供應(yīng)商組件的質(zhì)量，并確保操作員已正確組裝系統(tǒng)組件。這樣一來，制造商就能提高生產(chǎn)效率，避免返工和產(chǎn)品廢品。FasTest 技術(shù)銷售總監(jiān) Mark Spindler 表示：“如果在制造流程早期遺漏了泄漏，后期可能會(huì)造成很大的麻煩。想象一下，你正在組裝一臺(tái) 16 升的發(fā)動(dòng)機(jī)，一切進(jìn)展順利，但是由于氣缸蓋墊片安裝不正確，最終的泄漏測試失敗了。隔離發(fā)動(dòng)機(jī)、找出泄漏原因、拆卸系統(tǒng)并進(jìn)行維修所浪費(fèi)的時(shí)間是巨大的?！比绻孤y試流程保持一致，制造商將能夠使用泄漏測試對(duì)組裝或組件故障進(jìn)行根本原因分析，這將極大地改進(jìn)整個(gè)制造流程，并減少以后測試失敗的次數(shù)。

Leak testing provides verification that a manufactured product meets predetermined specifications that allow the part or system to operate as intended. This process is crucial to ensuring product quality and the safety of end-users. Additionally, a reliable leak testing process will help reduce product warranty claims and the cost of quality for systems manufacturers.  

There are also several production efficiencies benefits to an optimal leak testing process. A leak test will help validate supplier component quality and verify that operators have assembled system components correctly. In doing so, the manufacturer can improve production efficiency, and eliminate rework and product scrap waste. “If a leak is missed early on in the manufacturing process, it can cause significant headaches later,” says Mark Spindler, director of technical sales at FasTest. “Imagine you are assembling a sixteen-liter engine, everything is going well, but then the final leak test fails because the head gasket was not seated correctly. The amount of wasted time that goes into quarantining the engine, identifying the cause of the leak, disassembling the system, and repairing it, is enormous.”  If a leak testing process is consistent, manufacturers will be able to use leak tests to perform root cause analysis for assembly or component breakdowns, which will greatly improve the manufacturing processes as a whole and reduce the number of failed tests down the road. 

連接的重要性

The Importance of the Connection 

任何泄漏測試中最重要的方面是被測部件或系統(tǒng)上所有端口和孔的可靠、一致的防漏連接和密封。無論使用哪種泄漏測試，連接都至關(guān)重要；然而，制造商在開發(fā)泄漏測試流程時(shí)，連接環(huán)節(jié)常常被忽視。任何泄漏測試的目標(biāo)都是隔離待測試的組件或系統(tǒng)，而這只有在所有測試端口和孔洞均密封且無泄漏的情況下才能實(shí)現(xiàn)。

如果沒有適當(dāng)?shù)拿芊?，泄漏測試很容易出現(xiàn)誤報(bào)：即使被測部件本身無泄漏，泄漏測試也可能出現(xiàn)泄漏或失敗。誤報(bào)通常是由連接不當(dāng)或密封不嚴(yán)引起的，這會(huì)導(dǎo)致介質(zhì)滲入或滲出測試部件，從而導(dǎo)致測試失敗。許多泄漏測試失敗需要將部件報(bào)廢或從生產(chǎn)線上移出重新測試。潛在的產(chǎn)品廢品浪費(fèi)和返工，以及工藝瓶頸問題，都至關(guān)重要。幸運(yùn)的是，利用可靠的快速連接工具、可靠的密封和適當(dāng)?shù)乃骶呖梢暂p松避免誤故障。

The most important aspect of any leak test is a reliable, consistent leak-tight connection and seal for all ports and holes on the part or system being tested. This holds true regardless of the type of leak test being utilized; however, the connection is often overlooked when a manufacturer is developing their leak test process. The goal in any leak test is to isolate the component or system for testing, which can only be accomplished when all the test ports and holes are sealed and leak-tight.  

Without a proper seal, the leak test is prone to a false failure: leak tests that register a leak—or fail—when the part being tested is leak-free. A false failure is typically caused by an improper connection or profile seal, which allows media to seep into or out of the test part, resulting in a test failure. Many failed leak tests require the part to be scrapped or moved off the manufacturing line for retesting. The potential product scrap waste and rework, as well as process bottleneck considerations, are significant. Fortunately, false failures are easily avoided utilizing reliable quick connection tools, dependable sealing, and proper rigging. 

使用FasTest 連接工具是創(chuàng)建防漏密封的可靠、一致且高效的方法。這些連接工具經(jīng)過精心設(shè)計(jì)，可與特定類型的端口、螺紋、管子或孔建立可重復(fù)的防漏連接。連接工具允許用戶安全地進(jìn)行必要的連接，以運(yùn)行正確的泄漏測試，而無需擔(dān)心誤報(bào)或意外斷開。這些設(shè)備通過將測試設(shè)置時(shí)間縮短高達(dá) 95%，減少產(chǎn)品廢品和返工，并在不損壞測試件的情況下密封設(shè)備，顯著提高了泄漏測試過程的效率。

The reliable, consistent, and efficient method of creating a leak-tight seal is the FasTest Connection Tool. These Connection Tools are engineered to create a repeatable leak-tight connection to a specific type of port, thread, tube, or hole. The Connection Tools allow users to safely make the necessary connections to run a proper leak test without the concern of false failures or unintended disconnections. These devices significantly improve the efficiency of the leak testing process by cutting test setup time by up to 95%, reducing product scrap waste and rework, and sealing the devices without damaging the test piece.  

泄漏測試趨勢

Trends in Leak Testing 

工業(yè) 4.0 運(yùn)動(dòng)正在顛覆全球制造企業(yè)。擁抱工業(yè) 4.0 運(yùn)動(dòng)的企業(yè)的目標(biāo)是以更低的成本生產(chǎn)產(chǎn)品，提高生產(chǎn)效率，并提供比落后競爭對(duì)手更優(yōu)質(zhì)的產(chǎn)品質(zhì)量。在泄漏測試領(lǐng)域，工業(yè) 4.0 正在推動(dòng)許多關(guān)鍵領(lǐng)域的變革，包括智能測試連接工具的興起。

The industry?4.0 movement is disrupting manufacturing companies all over the world. The goal of companies that embrace the industry 4.0 movement is to produce goods at lower costs, drive throughput efficiencies, and provide superior output quality than lagging competitors. In leak testing, industry 4.0 is driving changes in many key areas including the rise of intelligent test connection tools. 

智能測試連接

Intelligent Test Connections 

為了收集更多工藝和泄漏測試數(shù)據(jù)，許多制造商開始依賴 FasTest ICON? 連接工具。這些連接工具內(nèi)置傳感器，使泄漏測試流程管理人員能夠收集數(shù)據(jù)并監(jiān)控連接點(diǎn)的測試操作。FasTest 先進(jìn)技術(shù)總監(jiān) Dustin Sirny 表示：“許多制造商通常希望獲得更多數(shù)據(jù)，但更重要的是，他們希望獲得可立即改進(jìn)工藝的可操作數(shù)據(jù)。密封件位置等數(shù)據(jù)點(diǎn)可以幫助工藝工程師立即識(shí)別泄漏測試過程中的問題并采取具體的糾正措施?！?/p>

借助智能快速連接工具，用戶可以確保在運(yùn)行泄漏測試之前已正確建立連接，并且已成功隔離測試部件或系統(tǒng)。Sirny 表示：“我們已經(jīng)看到許多制造商徹底改變了他們的泄漏測試方式，更重要的是，他們隔離制造部件的方式。智能測試連接還允許操作員監(jiān)控連接工具磨損部件的健康狀況，并優(yōu)化維護(hù)計(jì)劃，以避免代價(jià)高昂的停機(jī)?！?nbsp;

隨著工業(yè) 4.0 持續(xù)革新制造工藝和企業(yè)，泄漏測試方法也將隨之演變。“泄漏測試市場幾年來基本沒有變化”Sirny 說道?！半S著工業(yè) 4.0 的出現(xiàn)，我們十年來首次見證了泄漏測試的重大變化。我預(yù)計(jì)未來幾年我們將看到泄漏測試流程和最佳實(shí)踐的更多變化?！?/p>

To help gather more process and leak testing data, many manufacturers have begun relying on FasTest ICON? Connection Tools. These Connection Tools have incorporated sensors that allow leak test process managers to collect data and monitor testing operations at the point of connection. “Many manufacturers want more data to work with in general, but more importantly they want actionable data that can improve their processes immediately,” says Dustin Sirny, director of advanced technologies at FasTest. “Data points such as seal placement can help process engineers immediately identify problems in the leak testing process and take specific corrective actions.” 

With smart quick connection tools, users can ensure that the proper connections have been made and that the test part or system has been successfully isolated before running a leak test. “We’ve seen many manufacturers completely transform the way they are leak testing, and more importantly how they are isolating their manufactured part”, said Sirny. “Intelligent test connections also allow operators to monitor the health of the connection tool’s wear components and optimize maintenance schedules to avoid costly downtime.” 

As Industry 4.0 continues to revolutionize manufacturing processing and companies, leak testing methods will also evolve. “The leak testing market went largely unchanged for several years,” said Sirny. “With the emergence of Industry 4.0, we are seeing major changes in leak testing for the first time in a decade. I expect that we will see many more changes to the leak testing process and best practices in the coming years.”