Rotary leak tester

leakageautomaticin-line

Overview
The system provides largely automatic safety, function and leak testing for electric pumps intended for domestic use. It is engineered for inline production testing with minimal operator intervention, combining a dedicated turntable leak tester with a fast safety and function tester linked via PC network.

Industry
Gardening and small domestic pump manufacturing

Challenge
Short cycle times to match the production line pace, simple operation suitable for semi-skilled personnel, and minimal retooling for different pump variants. Leak testing requires significantly longer test time than safety and function checks, so the concept must avoid line bottlenecks.

Solution
The testing concept is split into two networked subsystems: a leak-test station with a turntable and two DUT supports, and a separate safety/function tester with drawer insertion. The turntable allows removal of a tested pump and insertion of the next unit while a test is running, reducing downtime and enclosing the test area for safety. Leak-test results are transmitted to the safety/function system so that all data are consolidated.

• The safety/function tester uses a drawer for quick DUT insertion; closing the drawer starts an automatic sequence
• Sequence: ground bond test, hipot test, insulation test, then functional test with mechanical actuation of the pump switch
• Automatic hot-stamping marks OK units
• Multiple leak-test systems can be connected to reduce average cycle time

Benefits

• Turnkey solution including DUT supports, adaptations and workplace design
• Intuitive, semi-skilled operation; single connection per DUT, then fully automatic testing
• Networked data storage in XML or Access format at a specified location
• Short cycle times through task division and turntable optimisation
• Minimal retooling for different versions and long service life
• Software-adjustable parameters and automatic daily dummy test for system validation
• Workplace safety compliant with EN 50191

Additional operational details
The system supports semi-automatic handling with low operator training requirements, automatic marking of OK units, networked storage and retrieval of test programs, and a mandatory daily dummy self-test that prevents production testing until passed.

Technical specifications

• Ground bond test: 10 – 30 A
• Hipot test: 5.5 kV AC / 6.0 kV DC / 4 mA (safety-current-limited)
• Insulation test: 6.0 kV DC / 4 mA
• Function test: single-phase, measurement range 15 A; measures voltage, current and power
• Leak test: dedicated leak-test system with turntable and two DUT supports
• Automatic marking: hot stamping punch for OK units
• Data storage formats: XML or Access; network-capable storage location
• Test programs: arbitrary number storable; automatic selection by product list
• Integration: option to connect additional leak-test systems via PC network
• Safety: enclosed leak-test area and workplace protection per EN 50191
• Automatic daily dummy test required before production testing