Twin-station leak test stands

The problem

Pressure-decay leak testing on automotive hose assemblies, to the OEM specification, across multiple part numbers running in batches.

What we built

Built around Cincinnati Test Systems Sentinel I28 instruments with custom fixturing, sensing, PLC control and HMI. Each part is tested for 45 seconds of pressure decay; the second station lets the operator load and unload one part while the other is under test. Barcode scanning selects the correct test program.

The first order used interchangeable fixture plates. The second order moved each fixture onto its own rolling cart — the plates were heavy to lift during changeover, and the carts removed the lift entirely.

The result

Removed manual lifting from changeover entirely. Four part numbers covered across the two generations of tooling.

Scope of work

• Mechanical design, fixture and tooling design
• Pneumatics and sensor integration
• Instrument integration and PLC programming
• Build, installation and documentation
• Operator training