Unit Dimensions: 32" W x  55" H x 62" D
Plus 25 feet of 6-inch diameter connecting hose.

 Side View

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Body Leakage Test Stand  - 2nd Generation                 

 


DESCRIPTION

An Automobile Manufacturer required a portable tester to measure the airflow leakage through a vehicle cabin in order to improve quality and reduce warranty expenses on wind, road and power train noise complaints.  

SYSTEM REQUIREMENTS


»  Provide Pressure or Suction within the Vehicle Under Test.

» Measure Air Mass Flow Range: 10 to 350 SCFM.

» Microsoft Excel™ Spreadsheet for Data Corrections and Data Storage.

»  User-friendly Test System Controller Software.

»  Highly Reproducible Results.

»  Two (2) System Check Nozzles.

»  Data Output Corrected to Nominal Day Conditions.

»  Custom Quick-Disconnect Fittings for Air Flow Hose, Filter and Check
    Nozzles.

»  Optional Software for Data Logging, Corrections and Storage. 

SOLUTION


Flow Systems designed and manufactured an Air Flow Metering System that employs a Thermal Mass Flowmeter.  The Test Stand controls the pressure inside the vehicle as it undergoes leakage testing, and the pressure inside the vehicle body may be positive or negative with respect to the local barometric reading.  The BLTS-2nd Gen is designed to deliver 10 to 350 SCFM of air at an accuracy of +/-3.0% of reading or better, with the maximum static pressure at the vehicle being +/-1.0 inches H2O@4°C. 

The Test Stand will allow the operator to change the flow direction.  Indicators on the Operator Interface Panel display when the system is in either Pressure or Suction Mode.

The Test Stand includes (2) Check Nozzles that allows for automated system verification. The optional test stand controller software includes the ability to set the flow at various rates and allow the operator to observe the percent difference between the flow nozzle and the flow meter reading.

The unit is easily positioned via push handles and (4) four lockable swivel casters.


Rear View with hose and filter

MICROSOFT EXCEL™ SPREADSHEET

 

 FUNCTIONS

» Correction of Flow Test Data Based on Ambient Conditions, Test
     Pressure, Flow Mode and Nominal Day Conditions.

»  Data Record Organization with Comments.

»  Check Nozzle Data Analysis.

»  Data Storage.

 

OPTIONAL LABVIEW™ SOFTWARE FOR AUTOMATED DATA REDUCTION
AND LOGGING:   BLTS-DATASOFT

FUNCTIONS

»  Improved Vehicle Pressure Set-Point Adjustment.

»  Button for Data Logging.

»  Indication of flow and Vehicle Pressure Stability.

»  Correction of Flow Test Data based on Ambient Conditions, Test
     Pressure, Flow Mode and Nominal Day Conditions.

»  Data Record Organization with Comments.

»  Check Nozzle Data Analysis.

»  Data Storage.

»  On-the-fly change between SI and English Units.

 
SYSTEM SCHEMATIC 

The following illustration shows the Pneumatic and Instrumentation Diagram (P&ID) of the test system:


Click to view enlarged image

 

 
USER INTERFACE 

This photo shows the operator interface of the test system:

 



SYSTEM LAYOUT

The following diagram illustrates the physical layout of the test system:

Click to view enlarged image

 
SPECIFICATIONS
 

Flow Modes:

 Pressure or Suction.
Flow Range:    10 to 350 SCFM. (283 to 9,911 SLPM)
Accuracy:  Estimated to be better than +/- 3 % of reading, with traceability to NIST
 standards.
Repeatability:  Estimated to be better than +/-0.5 % as defined as 2 standard deviations divided
 by the mean of 30 identical samples.
Vehicle Pressure Range:  0.25 to 1.0 inches H2O @ 4°C (13 to 25 mm H2O @ 4°C).
Accuracy:  +/-0.8% to +/-0.2% of reading, with traceability to NIST standards.
Weather Station:   Provides measurement of ambient conditions of pressure, temperature and
 humidity.
Microsoft Excel Spreadsheet for: » Storage of test records and user comments.
» Correction of raw test data to Nominal Day Conditions based on Ambient 
    Conditions.
» Analysis of Check Nozzle test data.
Cycle Time:   30 to 60 seconds depending on percent of maximum capacity.
Connecting Hardware from Test Stand to Vehicle:  » Air Flow: 6-inch diameter hose, 25 feet long.
» Pressure Line: 1/4-inch OD poly tube, 25 feet long.
Audit Check Nozzles:   Two (2) audit check nozzles are included with flow rates of nominal 35 SCFM
 and 236 SCFM.
Factory Acceptance Testing (FAT):  Final Test Stand setup and training at FLOW SYSTEMS facility for 1 day is
 included.
Crate:  Reusable with Fold-Down Ramp for local transport.  Constructed from
 Heat-Treated wood.


MODELS

» BLTS-2nd GEN (ENG):                       Units: SCFM, In H2O @ 4°C, In Hg@0°C, °F.

» BLTS-2nd GEN (SI):                          Units: SLPM, mm H2O @ 4°C, mm Hg@0°C, °C.

 

OPTIONS

»  BLTS-DATASOFT.

»  Software Customization including database integration, networking, SPC (Statistical Process Control), and more.

»  On-site Installation, Training, Commissioning and Upgrades.


 Front view with panel removed

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