Method and apparatus for detecting leaks

• US 6,840,086 B2
• Filed: 03/06/2003
• Issued: 01/11/2005
• Est. Priority Date: 03/06/2003
• Status: Expired due to Fees

• Current Assignee: Cincinnati Test Systems, Inc. (TASI Holdings, Inc.)
• Original Assignee: Cincinnati Test Systems, Inc. (TASI Holdings, Inc.)
• Inventors: Borntrager, Ryan R., McCoy, Fred Grant, Fazekas, Jonathan Mark
• Primary Examiner(s): CYGAN, MICHAEL T
• Application Number:
  US10/382,565
• Publication Number:
  US 20040173006A1
• Time in Patent Office: 677 Days
• Field of Search: 73/407, 702/51, 340/605
• US Class Current: 73/40.7
• CPC Class Codes: G01M 3/225 for welds
• CPC Class Codes: G01M 3/229 removably mounted in a test cell
• CPC Class Codes: G01N 1/26 with provision for intake from several spaces
• CPC Class Codes: G01N 7/10 by allowing diffusion of components through a porous wall and measuring a pressure or volume difference

Abstract

The present invention relates to a sensor apparatus configured to detect the presence of a gas, such as a tracer gas and a leak detection apparatus configured to detect the presence of a tracer gas and indicate the location of a leak. The leak detection apparatus may further be configured to quantify the leak rate at the leak location.

Claims

1. An apparatus for detecting the presence of at least one leak in a first region of a part under test and for localizing the location of the at least one leak, wherein a first side of the first region contains a tracer gas and is at a higher pressure than a second side of the first region such that the tracer gas will emanate through the at least one leak from the first side to the second side, the apparatus comprising:

a plurality of sensors positioned proximate to the first region, each sensor being configured to detect the presence of a tracer gas emanating from a leak and to provide a sensing signal;

a controller connected to the plurality of sensors and configured to provide a leak detection signal in response to at least a first sensor of the plurality of sensors detecting the presence of the tracer gas, the leak detection signal including leak detection information representative of the location of the leak in the first region based on the sensing signals received from at least the first sensor and a second sensor of the plurality of sensors; and

an indicator configured to provide a visual indication of the location of the leak, wherein the indicator includes a display configured to display a first represented of the part under-test and sensor icon positioned on the first representation, the sensor icon corresponding to a location of a first sensor which is proximate to the location of the leak.

2. The apparatus of claim 1, wherein the sensor icon provides a visual indication of the location of the leak.

3. The apparatus of claim 1, wherein the leak detection signal includes an indication of the leak rate of the at least one leak.

4. The apparatus of claim 3, wherein the plurality of sensors are coupled to a fixture, the fixture being configured to substantially enclosed the first region and the leak rate of the at least one leak being determined by finding the slope of the average concentration of tracer gas detected by the plurality of sensors over time.

5. The apparatus of claim 1, wherein each of the plurality of sensors is a thermal conductivity sensor.

6. The apparatus of claim 1, wherein the sensing signal provides an indication of the concentration of the tracer gas.

7. The apparatus of claim 1, wherein the plurality of sensors are coupled to a fixture, the fixture and the part under test cooperating to provide a non-sealed interior region.

8. The apparatus of claim 7, wherein the fixture is positioned relative to the first region of the part under test to substantially enclosed the first region and a leak rate of the at least one leak being determined by finding the slope of the average concentration of tracer gas detected by the plurality of sensors over time.

9. The apparatus of claim 1, wherein the controller and the plurality of sensors are connected by a network and the sensing signal for each of the plurality of sensors is a network message.

10. The apparatus of claim 1, wherein the first sensor corresponds of the sensor that detected the highest concentration of the tracer gas.

11. The apparatus of claim 1, wherein the first sensor corresponds to the sensor which first detected the presence of the tracer gas.

12. An apparatus for detecting the presence of at least one leak in a first region of a part under test and for localizing the location of the at least one leak, wherein a first side of the first region contains a tracer gas and is at a higher pressure than a second side of the first region such that the tracer gas will emanate through the at least one leak from the first side to the second side, the apparatus comprising:

a plurality of sensors positioned proximate to the first region, each sensor being configured to detect the presence of a tracer gas emanating from a leak and to provide a sensing signal;

a controller connected to the plurality of sensors and configured to provide a leak detection signal in response to at least a first sensor of the plurality of sensors detecting the presence of the tracer gas, the leak detection signal including leak detection information representative of the location of the leak in the first region based on the sensing signals received from at least the first sensor and a second sensor of the plurality of sensors; and

an indicator configured to provide a visual indication of the location of the leak, wherein the indicator includes a display configured to display a first representative of the part under test and a leak graphic positioned on the first representation, the position of the leak graphic corresponding to a location of a first sensor which is proximate to the location of the leak.

13. The apparatus of claim 12, wherein the leak graphic is an animated graphic configured to simulate the tracer gas emanating from the leak.

14. The apparatus of claim 12, wherein the first sensor corresponds to the sensor that detected the highest concentration of the tracer gas.

15. The apparatus of claim 12, wherein the first sensor corresponds to the sensor which first detected the presence of the tracer gas.

16. The apparatus of claim 12, wherein each of the plurality of sensors is a thermal conductivity sensor.

17. The apparatus of claim 12, wherein the sensing signal provides an indication of the concentration of the tracer gas.

18. The apparatus of claim 12, wherein the plurality of sensors are coupled to a fixture, the fixture and the part under test cooperating to provide a non-evacuated region.

19. The apparatus of claim 12, wherein the controller and the plurality of sensor are connected by a network and the sensing signal for each of the plurality of sensors is a network message.

20. An apparatus for detecting the presence of at least one leak in a first region of a part under test and for localizing the location of the at least one leak, wherein a first side of the first region contains a tracer gas and is at a higher pressure than a second side of the first region such that the tracer gas will emanate through the at least one leak from the first side to the second side, the apparatus comprising:

a plurality of sensors positioned proximate to the first region, each sensor being configured to detect the presence of a tracer gas emanating from a leak and to provide a sensing signal; and

a controller connected to the plurality of sensors and configured to provide a leak detection signal in response to at least a first sensor of the plurality of sensors detecting the presence of the tracer gas, the leak detection signal including leak detection information representative of the location of the leak in the first region based on the sensing signals received from at least the first sensor and a second sensor of the plurality of sensors, wherein the leak detection signal is provided in response to a determination that a threshold amount of the tracer gas has been detected by at least one sensor of the plurality of sensors and wherein the leak detection signal includes an indication of a first sensor, the first sensor being chosen based on a determination that the at least one leak is positioned proximate the first sensor.

21. The apparatus of claim 20, wherein the first sensor corresponds to the sensor that detected the highest concentration of the tracer gas.

22. The apparatus of claim 20, wherein the first sensor corresponds to the sensor which first detected the presence of the tracer gas.

23. The apparatus of claim 20, further comprising an indicator configured to provide a visual indication of the location of the leak.

24. The apparatus of claim 23, wherein the indicator includes a display configured to display a first representation of the part under test and a sensor icon positioned on the first representation, the sensor icon corresponding to a location of a first sensor which is proximate to the location of the leak.

25. The apparatus of claim 24, wherein the sensor icon provides a visual indication of the location of the leak.

26. The apparatus of claim 23, wherein the indicator includes a display configured to display a first representative of the part under test and a leak graphic positioned on the first representation, the position of the leak graphic corresponding to a location of a first sensor which is proximate to the location of the leak.

27. The apparatus of claim 26, wherein the leak graphic is an animated graphic configured to simulate the tracer gas emanating from the leak.

28. The apparatus of claim 20, wherein each of the plurality of sensors is a thermal conductivity sensor.

29. The apparatus of claim 20, wherein the sensing signal provides an indication of the concentration of the tracer gas.

30. The apparatus of claim 20, wherein the plurality of sensors are coupled to a fixture, the fixture and the part under test cooperating to provide a non-evacuated region.

31. The apparatus of claim 20, wherein the controller and the plurality of sensors are connected by a network and the sensing signal for each of the plurality of sensors is a network message.

32. A method of monitoring a part under test to determine whether a first region contains a leak, the method comprising the steps of:

locating a plurality of sensors proximate to the first region, each of the plurality of sensors configured to detect the presence of a tracer gas emanating from the leak and to provide a sensing signal;

monitoring each of the plurality of sensors to determine if the tracer gas is being detected by any of the plurality of sensors;

providing a leak detection signal in response to at least a first sensor of the plurality of sensors detecting the presence of the tracer gas, the leak detection signal including leak location information representative of the location of the leak in the first region based on the sensing signals received from at least the first sensor and a second sensor of the plurality of sensors; and

providing a first indication of the location of the leak, wherein the first indication includes displaying on a display a first representation of a part under test and a sensor icon on the first representation, the sensor icon corresponding to a location of a first sensor which is proximate to the location of the leak.

33. The method of claim 32, wherein the leak detection signal includes information representative of a leak rate and the method further comprising the step of providing a second indication of the leak rate in response to the at least first sensor of the plurality of sensors detecting the presence of the tracer gas.

34. The method of claim 32, further comprising the step of providing a leak rate signal in response to the at least first sensor of the plurality of sensors detecting the presence of the tracer gas, the leak rate signal including leak rate information representative of the leak rate of the leak.

35. The method of claim 34, wherein the step of providing the leak rate signal comprises the steps of:

determining average concentration of the plurality of sensors;

monitoring the change in average concentration of the plurality of sensors over a first time period;

determining the rate of change of the average concentration over time; and

comparing the rate of change of average concentration to known leak rates.

36. A method of monitoring a part under test to determine whether a first region contains a leak, the method comprising the steps of:

locating a plurality of sensors proximate to the first region, each of the plurality of sensors configured to detect the presence of a tracer gas emanating from the leak and to provide a sensing signal;

monitoring each of the plurality of sensors to determine if the tracer gas is being detected by any of the plurality of sensors;

providing a leak detection signal in response to at least a first sensor of the plurality of sensors detecting the presence of the tracer gas, the leak detection signal including leak location information representative of the location of the leak in the first region based on the sensing signals received from at least the first sensor and a second sensor of the plurality of sensors; and

providing a first indication of the location of the leak, wherein the first indication includes displaying on a display a first representation of a part under test and a leak graphic positioned on the first representation, the position of the leak graphic corresponding to a location of a first sensor which is proximate to the location of the leak.

37. The method of claim 36, further comprising the step of providing a leak rate signal in response to the at least first sensor of the plurality of sensors detecting the presence of the tracer gas, the leak rate signal including leak rate information representative of the leak rate of the leak.

38. The method of claim 37, wherein the step of providing the leak rate signal comprises the steps of:

determining average concentration of the plurality of sensors;

monitoring the change in average concentration of the plurality of sensors over a first time period;

determining the rate of change of the average concentration over time; and

comparing the rate of change of average concentration to known leak rates.

39. A method of monitoring a part under test to determine whether a first region contains a leak, the method comprising the steps of:

locating a plurality of sensors proximate to the first region, each of the plurality of sensors configured to detect the presence of a tracer gas emanating from the leak and to provide a sensing signal;

monitoring each of the plurality of sensors to determine if the tracer gas is being detected by any of the plurality of sensors; and

providing a leak detection signal in response to at least a first sensor of the plurality of sensors detecting the presence of the tracer gas, the leak detection signal including leak location information representative of the location of the leak in the first region based on the sensing signals received from at least the first sensor and a second sensor of the plurality of sensors, wherein the step of locating the plurality of sensors comprises the steps of coupling the plurality of sensors to at least a first fixture and positioning the first fixture adjacent the first region such that the first fixture and the part under test cooperate to provide a non-evacuated region.

40. The method of claim 39, further comprising the step of providing a first indication of the location of the leak.

41. The method of claim 39, wherein the first fixture is configured to substantially enclosed the first region such that tracer gas emanating from the leak is substantially retained by the first fixture.

42. The method of claim 41, further comprising the step of providing a leak rate signal in response to the at least first sensor of the plurality of sensors detecting the presence of the tracer gas, the leak rate signal including leak rate information representative of the leak rate of the leak.

43. The method of claim 41, wherein the step of providing the leak rate signal comprises the steps of:

determining average concentration of the plurality of sensors;

monitoring the change in average concentration of the plurality of sensors over a first time period;

determining the rate of change of the average concentration over time; and

comparing the rate of change of average concentration to known leak rates.

44. The method of claim 39, further comprising the steps of:

securing the part under test and introducing the tracer gas to the interior of the part under test; and

initiating a timer to define a length of a leak test, wherein the part under test is rejected if a leak is detected during the length of the leak test and the part under test is approved if the length of the leak test expires prior to the detection of a leak.

45. The method of claim 39, further comprising the step of sending the leak detection signal across a network to a remote device.

46. The method of claim 39, further comprising the step of providing a first indication of the location of the leak.

47. The method of claim 46, wherein the first indication is a visual indication.

48. A computer readable media for use in a leak testing application to determine which of a plurality of sensors is proximate to a leak in a part under test, the computer readable media comprising:

a software portion configured to load a data file corresponding to the location of the plurality of sensors, to monitor the plurality of sensors to determine if any of the plurality of sensors has detected the presence of a leak, to determine the location of the leak if at least a first sensor of the plurality of the sensors detected the presence of the leak, and to provide a visual indication of the location of the leak if at least the first sensor of the plurality of the sensors detected the presence of the leak, wherein the software portion is further configured to provide a first representation of the part under test and a first sensor representation of the at least first sensor positioned on at least the first representation of the part under test.

49. The computer readable media of claim 48, wherein the visual representation of the at least first sensor is a sensor icon.

50. The computer readable media of claim 48, wherein the first sensor representation is the visual indication of the location of the leak.

51. The computer readable media of claim 48, wherein the software portion is further configured to determine the location of the leak by determining which sensor of the plurality of sensors detected the maximum concentration of a tracer gas emanating from the part under test.

52. The computer readable media of claim 48, wherein the software portion is further configured to determine the location of the leak by determining which sensor of the plurality of sensors first detected the presence of a tracer gas emanating from the part under test.

53. The computer readable media of claim 48, wherein the software portion is further configured to determine the leak rate of the leak in the part under test.

54. The computer readable media of claim 53, wherein the software portion is configured to determine the leak rate of the leak in the part under test by determining an average concentration of a tracer gas detected by the plurality of sensors;

monitoring the change in the average concentration of the tracer gas detected by the plurality of sensors over a first time period;

determining a rate of change of the average concentration of the tracer gas detected by the plurality of sensors over a second time period; and

comparing the rate of change of average concentration of the tracer gas detected by the plurality of sensors to know leak rates.

55. The computer readable media of claim 53, wherein the software portion is further configured to provide a leak graphic positioned on the first representation of the part under test at a location proximate to the location of the leak.

56. The computer readable media of claim 48, wherein the software portion is configured to generate a network message for transmission to a remote device connected over a network.