Helium leak test for pin module

The test bench is used for a leak verification of the sealing of contact pins mounted in a metallic plate with helium gas.
The operator inserts  the work piece into the fixture and clamps it manually.
First a gross leak test will be performed, in order to sort out parts with obvious manufacturing faults.
Following the helium leak test will be done.
After finishing, the tested part needs to be taken out from the fixture by the operator. In case of a failed state, it has to be put monitored into a failed parts tray.

Leak test bench for helium-filled pressure dampers

Helium filled oval tubes are used to damp the pressure pulses which occur in fuel rails. The final testing of these pressure dampers requires a helium leak test. The leak test bench is a semi-automatic machine with a four-part rotary table. The operator inserts the parts to be tested by hand in the test part holders and then pushes the two-hand control to start the automatic test cycle. At the rough leak detection station the test parts are sorted into good and reject parts in order to avoid unnecessary contamination of the UL200 fine leak detector. Afterwards, the pressure dampers undergo a leak test in the test station. A pneumatically- perated marker punch marks all good test parts.


Helium leak test bench for fuel rails

After assembly, a fully mounted fuel rail is subject to a leak test with test medium helium. Any helium leaks present are detected by a helium detector and the leak of the fuel rail is measured. In order to keep the helium consumption as low as possible, most of the helium used during the leak test is recycled. The test bench generates a helium pressure of up to 210 bar. In order to ensure maximum safety, the test bench has a self-test function where the functional efficiency is checked by means of a calibration master. The test bench has an extractor unit in continuous operation which ensures that any contaminated helium is removed before it can cause measuring errors. At the end of the test cycle, test parts within the tolerance limit are marked accordingly.


Helium leak test machine

The machine is designed for leak testing of laser welded metal bellows. Additionally, the length and the elasticity rate of the bellows is determined. The test parts will be loaded on trays into the machine, automatically separated and moved into the 6-field rotary table, where each part is equipped with a double nest for holding the parts. First, the bellow is verified against processing or welding errors with a rough leak test by means of compressed air and the pressure drop principle. Afterwards, the leak value is measured in the helium leak station. Finally, the length and the elasticity rate of the bellow is checked before the part is offloaded from the table and placed into “passed” and “scrap” lines according to the test results.

Helium Leakage Test of GDI Pumps

This machine is used for leak verification with helium gas of laser welded fuel pump units.
The work piece will be put into one of the 6 pump carriers of the rotary table (3 carriers for each pump type) and following automatically moved into the leak test station.
First, the pump unit will be identified by reading the data matrix code. After this, a gross leak test will be performed, in order to sort out early enough parts with obvious manufacturing faults. Following the helium leak test will be done. If this is finished and after turning the rotary table again, the tested part can be taken out of the machine by the operator. He puts it to the right place according the test status. The discard of a failed part is verified by the machine.
It is possible to run two mechanically different pump types. The change-over for this is done automatically after selecting it in the user software. It is not needed to do any mechanical modification for this.


Helium Leak Test Machine

The test bench is used for helium leak verification of laser welded metal bellows. It is also possible to compress and strain bellows for adjusting the correct length. Different bellow types can be tested/adjusted. The parameter change-over is simply done by selecting the type in the user software. 
Leak test station:
The work piece will be loaded manually into one of 4 fixtures (two double stations). First, a gross leak test will be performed in order to sort out parts with obvious manufacturing faults. Afterwards the helium leak test will be done.
Compression station:
Up to 4 bellows can be loaded manually into the station. The parts will be compressed and strained in order to achieve the final length. If necessary, this cycle can be repeated several times automatically by parameter setup.


Sonplas GmbH- Sachsenring 57 - D-94315 Straubing - Deutschland - Tel: +49 (0) 94 21 / 92 75 - 0 Fax: +49 (0) 94 21 / 92 75 199 - info(at)

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