- Industry
- Automotive Manufacturing / Quality Control
- Solution
- Automated pressure-based leakage testing system
- Project duration
- February 2017 – May 2018
- Engineering focus
- Machine design, automation, pressure testing, PLC controls, quality assurance
- Application
- Exhaust manifolds for automotive and industrial engines
Exhaust manifolds that leak are worthless downstream, but the defects are small and the line does not stop. The system needed high detection sensitivity, fast cycles and automated loading so it could run continuously without an operator babysitting it.
It also had to adapt to multiple manifold configurations and survive a factory floor — vibration, dust and temperature swings, around the clock.
We built a pressurised, differential-pressure test arrangement with high-precision sensors: the manifold is sealed, pressurised with air or a suitable gas, and pressure change across the cycle is monitored against predefined limits. The system was calibrated using components with known leak sizes.
Robotic handling gave repeatable loading, accurate positioning and consistent cycle time, and the test cycle was optimised to under three minutes per manifold. An adjustable fixture system and modular test chamber let the same machine cover different engine platforms.
A PLC architecture managed pressurisation, test duration, sensor monitoring, leakage evaluation, pass/fail decisions and sequencing, with a touchscreen giving parameter selection, live status, results, history and troubleshooting information.
Project overview
Redyna Technologies designed an automated leakage testing machine for exhaust manifolds used in automotive and industrial engine systems.
The objective was to identify even very small leaks before exhaust manifolds progressed to subsequent production stages.
Key challenges
The system needed to provide:
- High leakage-detection sensitivity
- Fast testing cycles
- Automated loading and unloading
- Adaptability to multiple manifold configurations
- High repeatability
- Reliable factory-floor operation
- Resistance to vibration, dust and temperature variations
- 24/7 operational capability
- Cost-effective production integration
Redyna's engineering solution
The automated testing system incorporated:
- Pressurized test chamber
- Differential-pressure testing
- High-precision pressure sensors
- Adjustable component fixtures
- Automated loading and unloading
- Robotic handling
- PLC-based controls
- Touchscreen operator interface
- Programmable test parameters
- Automated pass/fail evaluation
Leakage detection technology
The exhaust manifold was placed inside a sealed testing arrangement and pressurized with air or another suitable gas.
The system monitored pressure changes during the test cycle. A pressure deviation outside the predefined limits indicated a potential leakage condition.
The system was calibrated using components with known leak sizes.
Automated production testing
To support high production volumes, the system incorporated automated component handling. A robotic arm provided:
- Repeatable loading
- Accurate positioning
- Reduced operator intervention
- Improved cycle consistency
Flexible fixture design
An adjustable fixture system was developed to accommodate different exhaust manifold geometries.
The modular test chamber allowed the system to be adapted to different engine platforms and manifold configurations.
Controls and software
A PLC-based control architecture managed:
- Pressurization
- Test duration
- Sensor monitoring
- Leakage evaluation
- Pass/fail decisions
- Test sequencing
Environmental and durability engineering
The machine was designed for continuous industrial operation. Engineering measures included:
- Industrial-grade materials
- Dust-resistant electrical enclosures
- Shielded cables
- Robust mechanical construction
- Environmental protection
- Long-duration stress testing
Testing and validation
The prototype was calibrated and validated using exhaust manifolds with known leakage characteristics. The system was tested for:
- Leakage sensitivity
- Repeatability
- False-positive and false-negative performance
- Long-duration operation
- Environmental resistance
- High-cycle production operation
Results and business value
The final system achieved leak detection down to 0.1 mm, a test cycle of under three minutes, automated loading and unloading, flexible testing for multiple manifold configurations and reliable 24/7 factory operation.
The automated inspection system provided a high-throughput quality-control solution that helped ensure defective or leaking exhaust manifolds were identified before reaching subsequent manufacturing stages.
Redyna's value — one engineering and implementation pathway
- Requirements
- Concept
- Detailed design
- Prototype
- Calibration
- Validation
- Line integration
Down to 0.1 mm
Leak detection
Under 3 minutes
Test cycle
24/7 factory duty
Operation