Dry Leak Tester

The MAHLE Dry Leak Tester employs a differential vacuum test method to do a quick leak check on vehicle fuel evaporative system for OBD-II compliance purpose. MAHLE Test Systems employs a statistical approach to quickly test a complete system or individual components for small leaks. The leak test is performed using vacuum or pressure, depending on the application. Convenient connections are available for both Capless and with-fuel cap systems.

With a typical leak test time of 25 seconds, The MAHLE Leak Tester’s robust design can support 100% high volume testing line rates. Real-time upload of all vehicle test results to plant servers allow for quality monitoring. Graphical test results analysis is available through ReportLogiq®, MAHLE’s reporting software. Fail limit is controlled by software, and results are reported to plant server for quality control. Power users with enhanced access are provided capability to locally change the fail limit.

  • Updated internal plumbing layout and hardware
    • Upto 6X separation between “No-Leak”, and “With Masterleak”
    • Meets repeatability requirements for production testing
  • 3 separate boxes for Power electronics, Pneumatics, and Reference
    • Easier user access during troubleshooting prevents potential damage during field service
    • Electric vacuum value controlled by tester software provides consistent test vacuum, and avoids erroneous handling
  • Air Ballast Tank with quick acting regulator
    • More precise leak rate measurement with higher repeatability
    • Eliminates shop air supply variation experienced at the plant line
  • Industrial I/O PLC controller
    • Proven PLC integration meets OEM requirements for Maintenance parts
    • Proactive alerts to prompt Maintenance team in case of tester down, with fault details
  • Enhanced internal filtration
    • Eliminates risk to debris related concerns on tester performance
    • Prognostic capability in software to track and prompt Maintenance technician for replacing filter parts
  • Cart-mounted (Lockable wheels) tester
    • Significantly reduced tester installation work and costs
    • Mobile implementation helps plant team evaluate multiple test station locations, with practical factors like shop air supply variation, ITM broadcast download issues.
  • Common Database Development
    • Easy to roll out software changes/ updates across all plants
    • Easier maintenance results in lower change costs
  • User-intuitive GUI Layout
    • Layout developed based on feedback from plant users
    • Visual-aid provided for easy troubleshooting/maintenance
  • On-screen buttons
    • Easy screen display configuration options available in most language fonts

Power Supply 110 V / 220 VAC, 50-60Hz, Single phase

Operating Temperature 14° to 122°F (-10° to +50°C); Storage: -4° to 158°F (-20° to +70°C)

Humidity 5% to 95%, RH; non-condensing

Dimensions W x H x D 22” x 71.5” x 25.5” (57.15cm x 181.61cm x 64.77cm)

Weight 185 lbs (84 kg)

External Connectors 19-pin Amphenol connector, USB (2X), Ethernet, (wireless 802.11 b/g, serial (RS232), Swagelok® pneumatic quick-connect

Display 15” industrial LCD monitor

Operator I/O Inputs Touch screen Monitor w/ on screen buttons, Virtual touch keyboard, mouse, USB inputs for scanner; keyboard and/or mouse; Outputs: LCD Monitor, Stack lights (test in progress/pass/fail), Printer (optional)

Wet Leak Tester

MAHLE Service Solutions employs a patented test method to quickly leak test a "wet" (fuel in tank) gasoline fuel evaporative system for small leaks (>.25mm orifice size). This tester offers an alternative option to previous generation "Smoke-type" evaporative system leak detector, by reducing leak detection effort/ time by typically 5 times. Large leaks (.1mm orifice hole) is detected in < 10 seconds, and Small leaks (>0.25mm orifice size) gets detected in <2.5 mins.

In vehicle plants, this tester helps production teams to continue building flagged vehicles through fuel-fill, without process distribution. Additionally, it provides a machine-based buy-off for the same target leak as MAHLE's main line "Dry" (no fuel in tank) tester. All fuel vapor emissions are self-contained for safety compliance, and test results are uploaded through wired / wireless connection to plant server.

A sensitive, hand-held hydrocarbon detector used with our proprietary "Smart pumping strategy", to help Repairmen quickly and accurately identify source of small leaks.

Our Leak Tester is compliant with US Federal OBD-II verification requirements for OEM evaporative fuel system leak checks during vehicle assembly, and also in-use emissions compliance program requirements. It is suited to support system development needs at Technical Centers for upcoming China-6 emissions requirements.

  • Patented test method with a faster leak test (large leak <10 secs, small leak < 2.5 mins) targeted to replace smoke testers for Evaporative leak checks
  • Plant production team can continue to fill fuel on failed cars, and fix them in Repair
  • Equivalent machine buy-off (same as main line “Dry” leak test) leak test for Evaporative system at Repair stations, with automated results upload to server
  • Portable cart mounted configuration, powered via UPS power supply and a wireless connection to any server
  • Production solution proven at multiple OEM assembly plants/ engineering applications
  • Test through fuel tank cap fitting or any other convenient access on the fuel evaporative system
  • Intrinsically safe tester design to capture fuel evaporative emissions, and re-use during leak source detection stage
  • Accounts for fuel blend effects, fuel vapor boil-off/ cool-down, and temperature variations
  • Fast test (<10 secs) for detecting large leaks, < 2.5 mins for small leaks, compared with existing smoke-type tester technology
  • Repeatable test through commanded Purge valve actuation
  • Enhanced leak source detection using sensitive Hydrocarbon sniffer, along with an integrated pump
  • Graphical test results analysis is available through ReportLogiq®, MAHLE’s reporting software

Power Supply 110 V / 220 VAC, 50-60Hz, Single phase

Operating Temperature +14° to 122°F  (-10° to +50°C); Storage: -4° to 158°F (-20° to +70°C)

Humidity 5 to 95% non-condensing

Dimensions (W x H x D) 20” x 20” x 86”

Weight 125 lbs (57 kg)

External Connectors 19-pin Amphenol connector, USB (2X), Ethernet, (wireless 802.11 b/g, serial (RS232), Swagelok® pneumatic quick-connect

Display 15” industrial LCD monitor

Operator I/O Inputs: Keypad, industrial mouse, touchscreen, 1 or 2D scanner (serial or USB). Multiple digital/analog input options available; Outputs: LCD Monitor, Stack lights (test in progress/pass/fail), Printer (optional)

Configuration FESTO industrial I/O modules; Housing with proximity sensor for VCI pod; Hand-held Hydrocarbon sniffer, with smart pump strategy