Leakages can have fatal consequences. To efficiently design production processes and to prevent costly and image-tarnishing recalls, components need to be tested early within the manufacturing process. Leak testing, for this reason, plays an important role in quality management.

The verification of seal integrity and the detection of leakages is an integral element of quality assurance across various sectors. Additionally, an early recognition of faulty parts during the manufacturing process can avoid unnecessary costs. Areas of application here include the testing of individual components, as well as complete systems either in serial production or within a laboratory environment. The sectors in question range from the auto industry (cylinder heads, transmissions, valves etc.) and medical engineering, right through to the plastics, packaging and cosmetics industries.

The German company ZELTWANGER Dichtheits- und Funktionsprüfsysteme GmbH is one of the most distinguished manufacturers of high-performance leakage testers. Depending upon the specific application, a range of leak testing procedures are optional, including the relative and absolute pressure methods.

Leak testing by the relative and absolute pressure methods

The relative or absolute pressure processes deliver the following decisive advantages:

  • compact test setup of small tare volume
  • high operating safety
  • extended measurement range
  • automation optional

During these procedures, the test item is subjected to a defined pressure. To be measured and analyzed over a set time is the pressure differential resulting from a leakage. In the relative pressure method, the difference to ambient pressure is decisive. When the test pressure is higher than ambient pressure, then we speak of overpressure testing. The terms negative pressure or vacuum testing then apply when test pressures register lower than ambient pressure. By the absolute pressure method, the pressure is determined relative to absolute vacuum.

When leak testing by either the relative or absolute procedures, ZELTWANGER also employs pressure measurement cells made by STS. The demands upon the technologies applied are rigorous, essential being:

  • outstanding signal processing
  • flexible pressure ranges
  • varying measurement methods (differential, relative and absolute pressures)
  • outstanding reliability

The ATM pressure sensor from STS meets these required specifications with its broad pressure range of 100 mbar to 1,000 bar and an accuracy of ≤ ± 0.10 %FS. But apart from these figures, its fail-safe ability and extremely good signal processing also represent crucial features. The modularity of STS sensors even offer manufacturers the option of straight forwardly integrating them for their own internal applications.

STS pressure transmitters, along with self-developed sensors from ZELTWANGER, are already integral to devices of the ZED series. These excel for both their versatility and precision. The ZEDbase+ device reliably measures, for example, relative, and differential pressures, as well as mass flow. Recorded test pressures, depending upon testing method, have ranged from vacuum to 16 bar. With relative pressure, even the slightest of pressure shifts from 0.5 Pa to 4 Pa can be detected. Besides these technical requisites, further decisive arguments in favor of STS are a reliable supply status, coupled with flexible and uncomplicated customer support – not to mention a major common ground between both of the companies involved. Our collective aim is always to provide customers with tailored solutions which exactly fulfill their exacting specifications.