Cyan Tec have vast experience in the design and manufacture of testing equipment, supplying both electronic and air testing machinery to a range of different industries. This technical article focusses on the basic principles of pressure decay testing, an industry known testing method that is used to detect leaks in components or assemblies, through a test station or on a production line.

Automated pressure decay leak testing is a popular method of testing the integrity of a sealed component. This process is often used in the manufacturing industry, where it is crucial to ensure that components are free of leaks before they are shipped to customers. In this article, we will discuss the process of automated pressure decay leak testing.

The first step in automated pressure decay leak testing is to prepare the component for testing. The component is connected to a test fixture and sealed off from the environment. The test fixture is then connected to a pressure source, which is used to pressurise the component.

Once the component is pressurised, the pressure is monitored to determine if there is any leakage. The pressure is monitored using a pressure transducer, which measures the pressure inside the component. The pressure transducer is connected to a data acquisition system, which records the pressure readings over time.

The pressure inside the component is then allowed to decay over a predetermined time period. The rate of decay is monitored using the pressure transducer and recorded by the data acquisition system. If the pressure inside the component decays too quickly, it is an indication that there is a leak.

Automated pressure decay leak testing is often performed using a programmable logic controller (PLC). The PLC is programmed to control the pressure source, pressure transducer, and data acquisition system. The PLC can be programmed to perform a variety of tests, including pressure decay, vacuum decay, and differential pressure testing.

One of the advantages of automated pressure decay leak testing is its speed and accuracy. The process can be completed quickly, allowing for high production rates. The accuracy of the process is also high, with pressure transducers able to detect leaks as small as 0.1 psi.

Another advantage of automated pressure decay leak testing is its repeatability. The process can be repeated m

ultiple times on the same component, ensuring that the results are consistent. This is important in the manufacturing industry, where consistency is crucial to ensuring the quality of the final product.
In conclusion, automated pressure decay leak testing is a highly effective method of testing the integrity of a sealed component. The process is fast, accurate, and repeatable, making it an ideal choice for the manufacturing industry. Additionally, the use of a PLC allows for a variety of tests to be performed, ensuring that components are free of leaks before they are shipped to customers.

Inside an application…..

When a high-profile automotive supplier needed a suite of customised leak testing systems for their latest engine components, they had no hesitation in contacting Cyan Tec Systems who had previously provided several automation machines for their UK factory. In order to fulfil the customers’ requirements, Cyan Tec provided a total of six individual leak testing machines, each designed to suit specific engine components.

To verify the quality of high-performance engines, it is necessary to perform accurate leak testing of components and assemblies, the most commonly used method being “pressure decay” which has been used for several decades to identify faults in sealing or component integrity. In this case, it was the high-level testing of the casting integrity that was required.

Cyan Tec has established a track record in automated leak testing, using third party leak testing equipment integrated into the production lines of many clients.  In particular, Cyan Tec has a strong relationship with Ateq, a well-known manufacturer of differential pressure decay leak testing equipment.

After assessing the requirements of the customer, Cyan Tec provided the six machines based around a modular design. Each machine is customised to suit one or more products, the machine construction providing a combination of guarding and safety light curtains to ensure that the operator is well-protected during the testing sequence.

Cyan Tec are an experienced manufacturer of laser processing systems, robotic automation and automated leak testing systems based in The Midlands, United Kingdom. Standard and custom systems are offered with a full service from design through manufacture, supported by a dedicated team of engineers. For more information, please contact our sales team on sales@cyan-tec.com or 01509 815186.

A suite of automation solutions from FANUC has proved integral to the delivery of an industrial-scale laser cutting cell commissioned by the UK’s Manufacturing Technology Centre (MTC). Constructed by system integrator Cyan Tec Systems, the demonstration cell comprises a 12m x 4m cutting table and, from FANUC UK, a six-axis robot, a computerised numerical control (CNC) system for the flatbed, and the laser, all contained within a laser-secure enclosure.

FANUC was the clear choice for automation partner on this project. “The main reason for working with FANUC was the fact that they could offer a seamless automation solution incorporating not just the robot but also the laser and motion system,” says Cyan Tec’s Grant Copson.

Bigger is better

The system was specifically commissioned by the MTC to sit at the upper end of industry expectations in terms of scale to showcase to visiting manufacturers just what is possible within automated laser cutting. There is real scope for the cell to be used within the aerospace and automotive industries, or any industry that requires large-scale pre-cut profiles. The construction sector could also benefit from cells of this size, in particular for precision cutting of profile sections for prefabricated buildings.

The cutting table and robot sit inside a large enclosure measuring 15.5m x 9m, but the space requirements go even further. The cutting table slides out an additional 13m ensuring that if an operator wants to load a 12m x 4m product, they have adequate access to do so – even if this requires the use of a crane or forklift truck.

Flexible by design

The laser cutting bed is designed to handle flat plate, while the FANUC M-20iB robot is deployed to cut tubular sections. The robot’s six axes are mounted on a floor track and driven synchronously with a FANUC seventh axis, allowing it to move up and down the tube being cut. The integrated laser is versatile enough to be applied to either tubular or flat metal and can be regulated to suit different material types.

Ray Timberlake, Sales Manager for factory automation products at FANUC UK, points out that industrial machines of this sort have traditionally been entrusted to plasma cutters, but in this application fibre laser equipment was the only possible solution to achieve the accuracy. “The choice of laser cutting is not so much about speed, but more about the quality of the finish that you achieve,” he explains.

Capable of handling payloads of 25kg, the FANUC M-20iB robot was chosen for its high precision and reach of up to 2m. There are cameras inside the enclosure to monitor production for quality and safety. In addition, the enclosure is laser-tight to protect against scattering from laser beams, with interlocked guard doors to ensure there is no access while the laser is running.

Strong collaboration

When the MTC commissioned Cyan Tec to construct the cell and specified its size and capabilities, the Cyan Tec team was quick to enlist the help of FANUC UK, with whom it enjoys a productive partnership.

“Over the last three to four years, we’ve built up a good relationship with FANUC,” says Grant. “They see us as a key integration partner, and we value the range and reliability of their automation solutions.”

FANUC UK’s strong after-sales support service is also integral to the partnership’s success, with the automation supplier able to offer an immediate response to any issues 24/7, anywhere in the country.

Overcoming project hurdles

In this instance, the sheer scale of the installation necessitated impressive operational responses from all involved. “The MTC had to make internal alterations to accommodate a cell of this size,” says Ray Timberlake. “The entire installation was first constructed at Cyan Tec’s workshop, commissioned there, then stripped apart, shipped and reconstructed at the MTC.”

Cyan Tec’s Grant Copson adds: “The main challenge was the physical size of the cell, as well as the detail of constructing guarding on that scale – ensuring it was safe and engineering a table that moves in and out automatically were paramount. The automation itself was less challenging, given that we are well used to applying these technologies.”

Precision with control

FANUC provided its 21.5-inch iH Pro human-machine interface (HMI) panel, along with all the motors and drives to control the flatbed CNC system, while Cyan Tec created its own control software for the entire cell, accessed through the HMI.

The ‘complete package’ that Cyan Tec sourced from FANUC included 30ib series controls, managing both axis and machine functions, and the FANUC beam switch, which directs the laser beam either towards the robot or the flatbed.

When selecting the control system, compatibility with laser – including, potentially, those from other suppliers – was an important consideration.

In fact, since the project completed, FANUC has launched its 0iFL series of laser-compatible controllers, which effectively perform the same role in an even more cost-effective way.

It is clear that this large-scale demonstration cell is the perfect showcase to help manufacturers across a range of sectors understand just what is possible within the field of automated laser cutting. To find out more, contact the MTC at laser@the-mtc.org.

Members of the Cyan Tec sales team joined the Trumpf open house at its impressive Luton facility from 30th November – 1st December 2022. The open house described as among the highlights of the sheet metalworking calendar provides an opportunity for OEMs and subcontractors to explore the latest developments in laser cutting, punching, welding, bending and laser marking technologies. Cyan Tec is a leading manufacturer of advanced industrial laser systems and works with Trumpf as a strategic partner bushing the boundaries of laser integration and taking advanced laser technologies into new sectors.

Cyan Tec has an enviable reputation as experts in the field of automated laser welding, cutting, cleaning, marking and engraving. CEO Clayton Sampson states “Cyan Tec operates at the cutting edge of industrial laser integration and we value the information exchange that occurs at such events which drives innovation in the field.”

Cyan Tec is a market leader in the supply of full turnkey laser systems to both industry and the research sectors. It supplies bespoke laser solutions to advanced industrial sectors including aerospace, nuclear decommissioning, automotive and battery technology. Cyan Tec also manufactures modular laser systems capable of processing metals, plastics, composites, ceramics, glass and fabrics. To learn more about bespoke or modular laser systems contact sales@cyan-tec.com.

Cyan Tec are once again delighted to show off their flexible laser processing machine, Flexlase, at Fanuc’s Open House event.

The Open House, running from the 2nd to the 4th of November 2022, will be hosted at Fanuc’s state of art facility in Coventry, UK. This is a fantastic opportunity for potential clients to meet the Cyan Tec team and understand more about the capabilities of the Flexlase machine.

The small footprint design has the ability to cut or weld (configured to suit the customer’s requirements), including the integration of a wide range of different laser sources. Cyan Tec’s vast laser experience will assist in the configuration of the machine such as; laser processing optics, laser power and component fixturing.

Given that Cyan Tec have a history of working in a wide range of industries – automotive (including E-mobility), aerospace, nuclear, battery technology, pharmaceutical and plastics – the Flexlase has been designed with this in mind and can be easily configured to suit a wide range of applications.

Additionally, Cyan Tec has an envious reputation in the supply of bespoke automation, inkjet and laser systems, so if the Flexlase machine doesn’t meet your specification, our team are also on hand to discuss your specialist requirements in more detail.