Air gaging can be described as the use of air flow and air pressure to determine the size of measured part’s dimensions. Air gaging relies on the laws of physics, which states that the volume of flow and the pressure are inversely proportional. As the clearance between the flow and the part increases, the pressure decreases and as the clearance decreases the pressure around the part increases.

The working principle of all air gaging applications require requlated air flow through a restriction(orifice) prior to being expelled through the nozzles of the air tool. Maximum air flow occurs when the nozzle of air is unobstructed by the workpiece. The air pressure which is also called the back pressure is at a minimum. During the time when the part is being measured, Air flow through the nozzle diminishes and the pressure builds up around the measured part. When the nozzle is completely sealed by the measured part, the back pressure reaches to the same level with the requlated air supply. The values of pressure and the flow can be drawn as a graph to explain things further in detail.

Consider the system shown above. Air is supplied at a constant pressure from the first region. The flow through the orifice and through the outlet of diameter d2 is governed by the seperation distance x between the outlet and the workpiece. The change in flow with x will be indicated by a change in the pressure downstream from the orifice p2. Thus, a measurement of this pressure may be taken as an indication of the seperation distance x. We assume the flow to be incompressible for the purposes of our analysis. The volumetric flow through the orifice may be represented by

There are two orifices in our case, the one in the first section and the one between the nozzle and the workpiece. We will designate the first area A1 of the orifice and A2 of the orifice. Than the previous equation becomes.

As the distance between the nozzle and the workpiece increase air flow increases and the pressure decreases around the workpiece. When this distance decreases the air flow decreases and the pressure increases. The linearity is well preserved around 0.4 < r < 0.9.

As Kao Metrology, our Air gaging instruments use the latest innovations in microchip technology to make fast and precise measurements. We use the latest chips and the sensors to measure your workpiece and deliver your results with industry standard formats. We produce Air gaging devices with as much channel as possible specific to your needs.

Leak testing plays a crucial role in ensuring safety and quality, especially in the electric vehicle (EV) industry. At Kao Metrology, we provide advanced leak testing devices that meet the high standards of industries like EV manufacturing, where precision is essential.

Why Leak Testing is Important for EVs

In electric vehicles, battery safety is critical. If there are leaks in the battery compartment, moisture can enter and cause damage like corrosion, short circuits, or even fires. Leak testing makes sure the battery is sealed properly, reducing these risks.

EVs also rely on complex electrical systems that must be protected from water and dust. Leak testing helps detect any potential gaps that could let contaminants in, which could lead to malfunctions. Efficiency is also important in EVs, and any leaks in systems like cooling or tire pressure monitoring can lower performance. By preventing leaks, manufacturers can maintain energy efficiency.

Finally, strict safety and quality standards in the EV industry require leak testing. This ensures that vehicles are safe, efficient, and meet all industry regulations, which also helps avoid expensive recalls or repairs.

Kao Metrology Leak Testing Solutions

At Kao Metrology, we offer a range of leak testing devices designed for different needs. Our devices are easy to use and come with features like high accuracy, large memory for storing test results, and data sharing with robots or PLCs.

One of our key products is the KD201 Leak Testing Device. It operates within a test pressure range of 0.2 to 7 bar and can detect leaks up to 999.99 cm³/min with high precision. It has a 7-inch color display, stores the last 10,000 test records, and allows you to share data easily with industrial systems.

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The KD250-251 Leak Testing Device offers similar features with additional options like manual or electric pressure regulators and easy-to-use internal regulators. It also stores up to 10,000 test results and has a user-friendly interface that operates like a mobile phone.

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For more complex needs, our KD350-360 Leak Testing Device provides two channels for leak testing, along with memory for 100 different parts and test settings. Like the other models, it includes easy data sharing options and visual and audio alerts to ensure accurate testing.

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Why Choose Kao Metrology?

Kao Metrology’s leak testing devices are designed to handle both small and large components. They are equipped with wireless or Ethernet connections, making it easy to share test results and integrate with your existing systems. Our devices are user-friendly, efficient, and come with one-button calibration for quick setup.

If you are looking for reliable and advanced leak testing devices for your manufacturing process, contact us to learn more.