Automated Leak and Flow Tester

Impetus to Invent

What do you do when you have separate leak, flow, calibration, and power testing stations, a shortage of labor, and a huge new order? Combine them all into one automated machine, of course! Headcount was reduced by four people, cycle time was cut in half, and the required labor skill set was significantly lowered by creating a single workstation that integrated all operations into one simple machine.
This system has the operator load the part, connect the solenoid leads, and hit start. The machine forms an airtight seal in two locations, applies various voltages, validates correct flows, and inserts an Allen wrench into the set screw to automatically adjust the flow until it is just right. If the part passes, it is released; otherwise, it is dumped into a reject bin. Whew! A lot happening in a tight space

Problem Solved

Labor shortage
High skill set required
Human error

Lessons Learned

We had never used a PLC-driven power supply to control voltage before. Thanks to the Acopian power supply, our PLC provided a variable input to the unit, which controlled the voltage. A very clean way to do this!

What Was Unique

Inventing a closed loop feedback system that was reading the flow real time while the servo motor adjusted the set screw automatically from a PID loop. Lots of fun and very rewarding!

What Was Challenging

Getting a hex wrench to automatically insert and engage with a set screw proved to be a little challenging. But modifying the geometry of the Allen wrench to add a little taper did the trick.