Developed an automated refrigeration leak detection workflow capable of validating leaks below 0.1 oz/year while increasing manufacturing throughput and reducing operator dependency.
Leak sensitivity threshold
Test sequencing and validation
Data storage and traceability
The challenge was detecting extremely small refrigeration leaks while maintaining production throughput and improving traceability.
Unit Scan + Badge Scan ↓ API Lookup ↓ Automatic Test Selection ↓ Safety Gate Verification ↓ Automated Decay Test ↓ Leak Detected? ↓ Safe Pressure Hold ↓ Operator Sniffer Search ↓ Sniffer Data Graphing ↓ Azure Database + Reporting
The system retrieves unit-specific configuration data automatically and determines the correct test sequence without operator decisions.
Safety gates are required and visually verified before the test sequence is allowed to begin.
AI-assisted vision systems verify that safety guards are correctly installed before automated testing begins, eliminating dedicated guard sensors and allowing flexible positioning across different unit configurations.
High-sensitivity pressure decay testing automatically identifies leaks exceeding strict quality thresholds.
Operators are only required when a leak is detected. The station automatically holds safe pressure for leak localization.
The system retrieves leak sniffer data automatically and graphs the results for troubleshooting and reporting.
All raw test data is stored in Azure databases for traceability, reporting, and future analysis.
Improved production quality and lower field issues
Automated testing reduced operator bottlenecks
Centralized reporting and historical analysis