When performing leak tests in manufacturing, the quality of the seal to the test specimen has a major impact on the reliability and repeatability of your measurement results. Even the most modern pressure regulators, mass flow meters, and leak detectors cannot compensate for poor sealing. Common factors such as confined spaces, rough surfaces, small diameters, or flexible components influence the design and layout of a leak-optimized connection to the test part.
At innomatec, we understand these challenges—and we have solutions for them. Our connec® quick-connect series was developed to solve a wide range of real-world sealing problems. Below, we examine six of the most common challenges and how you can overcome them to achieve better measurement results.
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1. Obstructive contours
Some components have features that make access to the opening to be adapted difficult: for example, a borehole/nozzle may be located close to an edge or wall of the component, which means that a standard connection cannot be used due to its dimensions.
The solution is a specially designed eccentric connection. Its unique geometry guarantees a seal for these special openings.
Another challenge is sealing openings/holes in sheet metal parts.
Special quick-connect fittings are used here, which grip behind the sheet metal edge of the opening with claws, thereby providing a counterhold/rear grip to seal the front side of the sheet metal via a gasket.
2. Small diameters
Sealing parts with small diameters requires careful consideration. The radial seal must apply sufficient pressure to seal, but must not reduce the diameter of the component. The aim is to achieve a maximum filling cross-section.
In these cases, a KA type quick-connect system with a radial seal is ideal. The external seal does not reduce the filling cross-section and ensures an even volume flow.
3. Large tolerances
Large tolerances pose a particular challenge in automatic operation.
Straight axis tolerances and angle tolerances in particular require an element that equalizes these tolerances above a certain value, namely a floating bearing.
The floating bearing centers the quick-connect system in the test piece opening or on the connection to be sealed, thus ensuring a secure seal.
4. Rough surfaces
Roughness, scratches, or notches on the sealing surface affect the sealing behavior. However, these problems can often be solved by selecting the right sealing material.
To achieve a secure seal, the solution is often to use seals made of softer material, which adapt to uneven surfaces and compensate for them to a certain extent.
A wider sealing surface also has a positive effect on the sealing performance, enabling repeatable, accurate tests.
5. Surface moisture
Moisture in the form of oil, coolant, or water makes sealing surfaces slippery and increases the risk of your quick-connect system slipping or sliding under pressure.
Special devices can be used to prevent the quick-connect system or the test specimen from moving during the test period. In this case, a slip lock ensures a secure hold on the test specimen, stability, and a leak-free connection.
6. Thin-walled or elastic test parts
Flexible components—such as elastomer parts, thin-walled tubes, or molded parts—are very sensitive to excessive force. Excessive sealing pressure can deform or damage them, which can lead to errors or incorrect test runs.
A quick-connect system that seals radially on a flexible hose must be equipped with an inner mandrel (type KA-S – sealing on the outer diameter) or a support sleeve (type KI-S – sealing on the inner diameter). This counterhold/support protects the test specimen against deformation and allows the seal to expand evenly. This protects sensitive test parts and at the same time ensures reliable sealing throughout the entire test process.
Ensure the reliability of your leak test with innomatec connec® seals
The performance of the leak test depends on the quality of the seal. With the right connector design, even difficult geometries, rough surfaces, moisture, or flexible parts can be tested with accuracy and repeatability. innomatec connec quick connectors are designed to solve these real-world sealing challenges through optimized radial sealing, adaptive alignment, soft sealing materials, and custom mounting options.
If you are ready to improve test stability and reduce false alarms, discover the entire connec connector portfolio and find the right sealing solution for your application.
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