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Multi-Application Leak Tester – MALT

TQC has engineered a compact, low-cost, multi-application leak testing module for over-pressure and vacuum leak testing and to suit most common differential pressure decay leak testing requirements. Originally designed and developed specifically to test small volumes (Micro Application Leak Tester), the range has now been expanded to include variants that allow testing of parts with larger volumes. (Multi-Application Leak Tester).

Leak Testing Instruments

Over several years of development, TQC has incorporated more than 80 bespoke MALT leak testing modules in both simple desktop fixtures and complex high-speed automated leak testing machines. Now, the Mk3 version of the MALT design is available for general release as a stand-alone leak test instrument (LT 201-Desk) or an OEM version (LT201/401). This commercial version of the LT201-Desk has been realised with the aid of an Innovate UK Smart Award.

The original MALT units were used predominantly in the medical sector but more recently the units have found a particular niche in testing small internal volume parts for the automotive, aerospace and defence sectors. A good example is the leak testing of in-the-tyre pressure sensors.

The leak tester can resolve to better than 0.1 Pa pressure and time measurement of 1 millisecond. Leak rate resolution is dependant on volume but can be better than 0.01 mm3/s (0.0006 ml/min). Typically, with a rigid part, MALT units are sensitive enough to reliably measure leakage of 1.0 cubic mm per second on a volume of 5cc and smaller leak rates for smaller volumes .

MALT Leak Tester Unit

Leak Tester UnitLT201 – Desk Key Points

  • Pressure decay leak test module for small volumes.
  • Single compact rugged housing (25x9x17cm); can be mounted close test fixture.
  • High sensitivity.
  • Test pressures from full vacuum to 3bar.
  • Comms: Digital I/O, Ethernet, Serial RS232.
  • Data logging to in-built SD card accessible by FTP.
  • Web interface for configuration.
  • Configuration of the leak test unit, real-time monitoring and recording of data from mobile devices.
  • Predominantly used with compressed air but can be used with other common test and tracer gases.

LT201 / LT401 Leak Test Modules

The OEM version of the MALT instrument is for integration into leak test machines and systems whereby the measuring valve module can be mounted directly onto the seal tooling to minimise pipe volume.

MALT Leak Test OEM Unit

Leak Tester Unit LT201 / LT401 Key Points

  • Pressure decay leak test module for small volumes.
  • Compact so can be mounted very close to the test fixture.
    • Controller (15x5x15cm);
    • Valve module (5x10x11cm)
  • Easy to bank multiple modules to test multiple parts.
  • High sensitivity.
  • Test pressures from full vacuum to 3bar.
  • Comms: Digital I/O, Ethernet, Serial RS232.
  • Data logging to in-built SD card accessible by FTP.
  • Web interface for configuration.
  • Configuration of the unit, real-time monitoring and recording of data from mobile devices.

MALT – Leak Tester Configuration

Below are a series of screens that are accessible by directly connecting a laptop with an Ethernet cable or from any mobile device by connecting powered wifi through Ethernet connection. By using these pages a whole range of the MALT’s capabilities can be configured.

MALT Configurations / Control Options

  • Shock filling capability to force volumes into earlier stabilisation
  • Volume dosing for testing hermetically sealed parts.
  • Multi program configuration allowing multiple tests for different product variants and settable variable test pressure with an electronic pressure regulator.
  • Function to cascade tests to identify blockage and test multi-cavity parts
  • The units have the capability to have programmable inputs to allow sensing of switches from the fixture to inhibit the test start.
  • The units have the capability of controlling an electrical output for initiating a pass mark.
  • The units can be supplied to run from a 24V DC supply, 110V AC or 220V AC.
  • The units are supplied complete with either a precision regulator or an optional electronic pressure regulator.
  • Additional I/O, a total of 4 additional inputs and 8 additional outputs can be configured to allow for limited fixture control directly from the MALT. No need for an additional PC or PLC controller.
  • Results data can include a part serial number read by barcode reader for traceability.

Run these short video clips to show the graphical capability showing a part that passes and one that fails.

MALT display for Passed Part
MALT display for Failed Part

TQC also have available a remote button box as shown here. The unit gives the user the ability to have a control unit close by and has a BCD switch to be able to easily select pre-configured tests.

MALT remote button box for leak testing

If you have a specific requirement for a leak testing system contact TQC’s experienced Engineers. We can discuss and advise on your specific application, we can advise on the suitability of a particular technique, the fixturing, sealing and perhaps also provide a proposal for a complete turnkey project. Use the email or phone contacts below to discuss your project now.

To find out more about how we can help you with your Leak Testing needs:

We build all machines in-house, applying our 35+ years experience in specialised test and automated handling machines to the engineering projects we undertake. We offer customer support, backup and service call-out for all projects, whatever the size.

Get in touch with us to discuss your requirements and we will be happy to offer our professional advice and visit you at your site.