Body Leakage Test Stand

Product Summary

The Body Leakage Test Stand – 2nd Generation is an air flow measurement system that specifically for vehicle manufacturers that:

  • measures vehical cabin air leakage using an automotive mass air flow sensor
Key Features
  • Measures Air Mass Flow Range: 10 to 350 SCFM
  • Accurate Measurement (±3.0%)
  • Small footprint and minimal facility requirements
  • Highly Repeatable Results (±0.5 %)
  • Provide Pressure or Vacuum within the Vehicle Under Test
How does this test stand work?

This 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.

It 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 water at 4°C.
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.

It includes two flow nozzles that allows for automated system verification.

The test stand controller software includes a mode of operation to set the flow at various rates and allow the operator to observe the percent difference between the flow stand and theflow meter reading.

Depending on the percent difference, the software will display a “PASS” or “FAIL”.

Which Test Stand Should I Choose?

For information comparing the two available body leakage test stands, refer to the Body Leakage Test Stand Product Comparison.

Traceable to NIST

All Flow Systems air test stand sonic nozzles and instruments (P, T & RH) are traceable to National Institute of Standards and Technology (NIST).

System Specifications

The second generation of the Body Leakage Test Stand -2nd Generation comes in two models:


Model Code Details
BLTS-2nd GEN (ENG) Units: SCFM, inches of water at 4°C, inches Hg at 0°F, °F.
BLTS-2nd GEN (SI) Units: SLPS, Pa, kPa, °C.

Both of the “ENG” and “SI” models mentioned above have the following features:


Specification Value(s)
Flow Modes Pressure, Suction, or Mass Flow
Flow Range 10 – 350 SCFM (4.7 to 165 SLPS)
Accuracy Estimated to be better than ±3.0% of reading, NIST traceable
Repeatability Estimated to be better than ±0.5%, defined as 2 standard deviations divided by the mean of 30 samples
Vehicle Pressure Range 0.25 – 1.0 inches of water at 4°C
127.5 to 250 Pa
Weather Station Provides measurement of ambient conditions of pressure, temperature and humidity
Cycle Time 30 – 60 second, capacity dependent
Flow Hose 6″ diameter hose, 25 feet long
Pressure Line 1/4″ OD poly tube, 25 feet long
Audit Check Nozzles Flow Rates Two audit check nozzles are included with flow rates of nominal 35 SCFM and 350 SCFM
Factory Acceptance Testing (FAT) Setup and training at FLOW SYSTEMS factory for 1 day is included
Unit Dimensions 32″ W x 55″ H x 62″ D plus 20 feet of 6-inch diameter connecting hose

Built with Commercial Off-The-Shelf (COTS) Components

All Flow Systems air flow test system designs, the test system controller, data acquisition and control subsystems, and all instrumentation are standard and readily available Commercial Off-The-Shelf (COTS) items. This ensures that service or replacement of any item can be achieved in a timely manner, providing for high availability of our products. When applicable, this includes all of the Unit Under Test related instrumentation specified by the customer.

Software

National Instruments LabVIEW Logo
Control System Operator Interface

The system controller software controls and records air flow to the vehicle cabin, then records the data to the specified data storage location.
Controller software is written using National Instruments LabVIEW™.

Report and Store Live Data
  • On-screen test results displayed in real-time in tabular or graphic modes
  • Allows the operator to read all system sensors, and read status and error messages
  • Tests can be run manually or on automatically (the system controls the test), with several user-specified parameters
Measure Cabin Body Leakage Using Two Types of Tests
  • Pressure: Air is pushed into the cabin of the vehicle
  • Suction: Air is vacuumed out of the cabin of the vehicle
Customize Controller Software and Integrate Data
  • Controller software can be customized to fit a wide variety of customer needs
  • Data can be integrated with customer’s local databases and/or information systems
Data Storage Formats
  • Standard storage format is SQL database
  • Customized data storage options available
Monitor Ambient Conditions
  • Measures ambient barometer, temperature and relative humidity.
Troubleshoot Issues Using Internet-based Support – Optional
  • After connecting the test stand to the internet, receive technical support from Flow Systems
Additional Software Screenshots
Production Screen: Graph View

Production Screen: Graph View

Facility Requirements

The facility requirements below are to be supplied by the customer at the installation site.


Electrical Power: 100-240 VAC/50-50Hz/1ph, 15-30 Amp
Photos & Schematics

Additional Software Screenshots

Unit Dimensions: 32″ W x 55″ H x 62″ D

Body Leakage Test Stand – 2nd Generation

Side View

Body Leakage Test Stand Side View

Control Panel

Body Leakage Test Stand

Front View with Panel Removed

Body Leakage Test Stand – 2nd Generation

Pneumatic and Instrumentation Diagram

Download PDF Pneumatic and Instrumentation Diagram

Pneumatic and Instrumentation Diagram

Physical Diagram

Download PDF Pneumatic and Instrumentation Diagram

Physical Diagram

Options

The following is a list of options available for this test stand:

  • On-site installation, training, commissioning and upgrades
  • Software customization