A new dimension in gas bubble detection in water basins
MACEAS’ ultrasonic leak testing provides accurate leak detection and localisation at minimal operating costs, making it ideal for automated processes. Take advantage of this low-maintenance solution to increase the efficiency and quality of your manufacturing process and quality assurance.
Leak testing is a crucial step for quality assurance in industrial production. With its ultrasonic leak testing, MACEAS offers a modern, high-precision solution that both detects leaks and pinpoints their exact location. By using compressed air as the test gas and robust, maintenance-free ultrasonic sensor technology, our customers benefit from minimal operating and maintenance costs. This method is ideal for fully automated production processes and ensures transparent, reliable testing – without the need for periodic calibrations or time-consuming preparation of the test parts. You can trust MACEAS to make your production processes more efficient and your products more durable!
Your benefits at a glance:
- Objective, transparent leak testing
- Several parts can be tested in one basin
- Direct, localising measurement method
- Low test gas costs thanks to use of air or nitrogen as test gas
- Semi-automatic or fully automatic leak testing systems
- Low-maintenance ultrasonic system
- No periodic calibration required
- No vacuum components necessary
- Low operating costs
- Product holder for other product variants
How ultrasonic leak testing works
Detect and locate leaks down to 1 · 10–4 mbar · l/s using ultrasonic leak testing
In simple terms, ultrasonic leak testing can be compared to the familiar “bicycle tyre” method: If a bicycle tyre has a puncture, fill it with air and submerge it in water to find the leak by looking for bubbles rising to the surface; then it can be sealed. Of course, ultrasonic leak testing is a highly sophisticated industrial technology that only uses this approach for illustrative purposes. In practice, components such as tanks, pipes and housings are tested for leaks in series production in a fully automated and precise manner – millions of times over, for example in the automotive industry or building engineering.
Visualisation of ultrasonic gas bubble detection in a water basin
Ultrasonic leak testing
Ultrasonic leak testing enables precise, reliable detection of gas bubbles in a water basin. This operator-independent, automated process minimises human error and increases efficiency even with low leak rates.
New USBD4000
MACEAS-Sensoreinheit für die Ultraschall-Dichtheitsprüfung:
MACEAS sensor unit for ultrasonic leak testing: Latest testing technology with 3D leak detection and related software
USBD4000
What does that mean? 25 years of experience in ultrasonic leak testing in compact, next-generation hardware and software:
- Next-generation hardware that is easy to install and compatible with all MACEAS systems
- Preventive maintenance with real-time, long-term data
- Improved signal processing and interference suppression
- Precise leak detection and real-time measurement results
- Efficient error handling and user management
Complete package comprising measuring technology and software
from € 57,300.00
Flexible system – precise results
The USBD4000 offers a reliable solution for a broad range of requirements. The basic structure and scope of delivery remain the same, but the number of ultrasonic sensors varies. This determines the size of the sound and test field and consequently the maximum size and the number of workpieces to be tested. This enables us to tailor the inspection perfectly to your individual needs – for maximum precision and efficiency.
| USBD3000 Frühere Generation | USBD4000 Neue Generation |
|
|---|---|---|
| Real-time display of measurement results |  | |
| Diagnosis and remote maintenance without interrupting production | | |
| Next-generation, high-performance hardware platform | expired | |
| Next-generation, high-performance hardware platform | | |
| Less sensitive to faults thanks to compact design | Up to 10 m measuring cable | approx. 25–30 cm |
| Spatial leak detection | | |
| Combinatorial parameterisation to reduce the amount of data | |
| Variante | Preis |
|---|---|
| 16 sensors | 57,300.00 € |
| 20 sensors | 60,000.00 € |
| 24 sensors | 62,750.00 € |
| 29 sensors | 66,500.00 € |
Key advantages of MACEAS ultrasonic leak testing
Automation instead of manual inspection
Our ultrasonic leak testing automates the entire process and monitors every point of the test piece throughout the entire measuring time. This eliminates time-consuming manual checks and ensures that potential leaks are not overlooked.
Precise leak detection
Compared to the helium sniffer solution, where each position is only briefly scanned and slight air turbulence can delay the detection of leaks, our ultrasonic measurement permanently checks every relevant measuring point with a guaranteed leak rate. This allows even the smallest leaks to be reliably located, significantly improving quality assurance.
Savings through efficiency
Continuous monitoring of all measuring points significantly reduces testing times. At the same time, maintenance and operating costs are reduced compared to more complex helium sniffer solutions. This optimises resource utilisation and increases the cost-effectiveness of series production.
Technical data
Active sensor unit
The active sensor unit consists of a sensor holder with up to 29 ultrasonic sensors, screened-off sensor cables, active sensor electronics (with measuring electronics) and a protective hood.
Control computer with Windows 10 or Windows 11 IOT
The control PC is used for higher-level measurement sequence control and enables the customer to operate the system intuitively. We also carry out the entire parameterisation via the control PC. Remotely as well, if required.
Active sensor electronics
| Power supply: | 24 VDC |
| Power consumption: | 10 W |
| Interface: | 100 Mbit/s Ethernet |
| Sensor connections: | 32 SMA-Buchsen |
| Signalling: | 3 status LEDs |
Intuitive control and monitoring via display
The system is equipped with a user-friendly display for easy operation and monitoring of the test process. The display can be used to set important parameters and view real-time leak detection data, enabling efficient, precise control.
Integration in a production line for quality control
The sensor unit for ultrasonic leak testing can be easily integrated into existing production lines and enables automated inline quality assurance. The precise detection and localisation of leaks during the production process ensures seamless control without interrupting the workflow.
Applications
MACEAS ultrasonic leak testing offers a wide range of applications in various industries – from the automotive industry to the energy sector. Regardless of whether it is filler pipes, fuel tanks, hot water tanks or battery packs – this innovative test method ensures the highest quality and safety through precise leak detection and localisation for a wide range of products and industries.
