JP2006522335A - Method and apparatus for detecting gas - Google Patents

Abstract

The present disclosure includes a sensor device (300, 300 ′, 300 ″, 450) configured to detect the presence of a gas such as a tracer gas, and configured to detect the presence of the tracer gas and indicate a leak position. Leak detection device (100, 100 '). The leak detection device (100, 100 ') may be further configured to quantify the leak rate at the leak location.

Description

  The present invention relates to a method and apparatus for detecting the presence of a gas, and more particularly to a method and apparatus for detecting the presence of a tracer gas in a leak test environment.

  In a conventional leak test apparatus, either the internal region or the external region of the part under test is placed at a higher pressure than the other of the internal region or the external region of the part under test. Therefore, if there is a leak in the part under test, the gas flows from the high pressure side of the part under test to the low pressure side of the part under test. One way to monitor this gas flow and thereby detect the presence of a leak is by a pressure drop device that monitors the pressure on the high pressure side of the part under test. A decrease in pressure can indicate a leak. Another method uses an apparatus based on mass spectrometry to test for the presence of tracer gas on the low pressure side of the part under test. Tracer gas is introduced to the high pressure side of the part under test.

  Such a device provides an indication to the device operator whether there is a leak in the part under test or at least a leak in the part under test above a predetermined threshold. Normally, the customer designates a threshold value, and the operator sets the device threshold value. If the operator of the leak test device receives an indication from the leak test device that the part under test is unacceptable leak, i.e. contains a leak above the threshold, the operator knows that the part under test has failed, The operator places the awaiting part for further testing. However, the operator does not know about the leak location, or whether the leaks of parts subsequently rejected are at approximately the same location or at different locations.

  Conventionally, further testing is required to determine the leak location. After the leak location is determined, manufacturing process changes can be made to minimize the number of rejected parts in the future. The leak location is usually determined by one of two methods. First, for large leaks, the leak location is determined by pressurizing the failing parts and sinking the failing parts into a water bath. The leak location is determined based on the presence of bubbles arising from the leak site. Second, for small leaks, the leak location can be determined by pressurizing rejected parts with tracer gas and passing through a tracer gas detector, such as a sniffer device, over areas where there is a possibility of leaking rejected parts. . The tracer gas detector draws gas close to the probe of the tracer gas detector into the probe and passes it through the detector to detect the presence of the tracer gas. One way to draw gas in proximity to the probe is by a fan unit that draws gas into the probe and then passes through the detector. As a result, the site of leakage is recognized and, in some cases, the manufacturing process is changed.

  The above two-step process requires additional resources, delays the determination of leak locations on any part under test, and delays the determination of repeatability of leak locations between rejected parts . Furthermore, the above two-step process is very operator dependent in that the operator must visually recognize the leak, indicate the location of the leak, and perform a consistent test procedure on each rejected part. high. Furthermore, in each operator's ability to recognize leaks and indicate leak locations, the results will vary from operator to operator.

  In addition, conventional devices often use mass spectrometry equipment to detect the presence of leaks because of the need to detect small amounts of tracer gas. In such an apparatus, it is necessary to draw the gas located on the low pressure side of the part under test into the sensing element and analyze the gas to detect the presence of the tracer gas.

  Therefore, there is a need for a leak detection device that provides an indication of the leak location in a part under test, generally simultaneously with the initial leak test of the part. There is a further need for a leak detection device that provides an indication of leak location and an indication or measurement of leak rate. In addition, there is a need for a cost effective leak detection device.

  In one exemplary embodiment, the present invention includes a leak test apparatus configured to detect the presence of a leak in a part under test. In one example, the leak test apparatus of the present invention is further configured to determine a leak location in the part under test. In another example, the leak test apparatus is further configured to determine both the leak location in the part under test and the leak rate of the corresponding leak.

  In another exemplary embodiment, an apparatus for detecting the presence of at least one leak in a first region of a part under test and identifying at least one leak location, wherein the first side of the first region is a tracer. A device that contains gas and is at a higher pressure than the second side of the first region, and through which the tracer gas flows out from the first side to the second side through at least one leak, A plurality of sensors positioned proximate to a region, each sensor configured to detect the presence of tracer gas flowing out of the leak and provide a sensing signal; A controller connected to the. The controller provides a leak detection signal in response to at least a first sensor of the plurality of sensors detecting the presence of the tracer gas, the leak detection signal including at least the first sensor and the second of the plurality of sensors. Based on the detection signal received from the sensor, leak detection information representing the leak position in the first region is included. In one example, the apparatus further comprises an indicator configured to provide a visual indication of the leak location. In one variation, the indicator includes a display configured to display a first representation of the part under test and a sensor icon positioned on the first representation, wherein the sensor icon is a leak location. Corresponds to the position of the first sensor close to. In another variation, the indicator includes a display configured to display a first representation of the part under test and a leakage graphic positioned on the first representation, where the location of the leakage graphic is Corresponds to the position of the first sensor close to the position.

  In one exemplary method, for a method of monitoring a part under test to determine if a first region contains a leak, the method comprises placing a plurality of sensors proximate to the first region. Each of the plurality of sensors is configured to detect the presence of tracer gas flowing out of the leak and provide a sensing signal, and further, the method determines whether the tracer gas is detected by any of the plurality of sensors. Monitoring each of the plurality of sensors to determine and providing a leak detection signal in response to at least a first sensor of the plurality of sensors detecting the presence of the tracer gas. The leak detection signal is a leak detection information representing a leak position in the first region based on detection signals received from at least the first sensor and the second sensor of the plurality of sensors. Including the. In one example, the method further comprises providing a first indication of the leak location. In one variation, the first display includes displaying a first representation of the part under test and a sensor icon positioned on the first representation on the display, wherein the sensor icon is leaked. Corresponds to the position of the first sensor close to the position. In another variation, the first display includes displaying on the display a first representation of the part under test and a leak graphic positioned on the first representation, where the position of the leak graphic is: Corresponds to the position of the first sensor close to the leak position.

  In yet another exemplary embodiment, a computer readable medium for use in a leak test application for determining a plurality of sensors proximate to a leak under a part under test is a data file corresponding to the positions of the plurality of sensors. And monitor multiple sensors to determine which of the multiple sensors detected the presence of a leak, and if at least a first sensor of the multiple sensors detects the presence of a leak, And a software portion configured to provide a visual indication of the leak location when at least a first sensor of the plurality of sensors detects the presence of the leak. In one example, the software portion further provides a first representation of the part under test and a first sensor representation of at least the first sensor positioned on the at least first representation of the part under test. Consists of. In another example, the visual representation of at least the first sensor is a sensor icon. In yet another example, the software unit further determines the leak position by determining which of the plurality of sensors detects the maximum concentration of the tracer gas released from the part under test. Composed. In a further example, the software unit further determines the leak position by determining which of the plurality of sensors first detects the presence of the tracer gas emitted from the part under test. Composed. In yet a further example, the software portion is further configured to determine a leak rate of the leak in the part under test. In one variation, the software portion is further configured to provide a leak graphic positioned at a location proximate to the leak location on the first representation of the part under test.

  In a further exemplary embodiment, the present invention includes a sensor device configured to detect the presence of a gas such as helium or hydrogen. In one example, the sensor apparatus includes a sensor controller and is a network-capable sensor apparatus, and the sensor apparatus can share information with other devices via the network. In another example, the sensor device is configured to detect the presence and concentration of a gas such as helium or hydrogen. In yet another example, the sensor device is configured to be incorporated into a component that detects the presence of a gas.

  In a further exemplary embodiment, a sensor device for detecting the presence of a leak in a part under test detects the presence of a housing and the tracer gas by detecting the presence of the housing and the tracer gas when the part under test is pressurized with a gas containing a tracer gas. A sensor configured to generate a signal, at least a first portion of the sensor housed in the housing, and an I / O interface coupled to the housing, the I / O interface corresponding to the analog output. And a sensor device is connected to the sensor and the I / O interface and is configured to provide an output signal based on the detection signal generated by the sensor. A sensor controller configured to generate an I / O interface With the network via a connection to determine whether there is configured to generate a data packet transmitted through the network when the network is present, the sensor controller is housed in a housing. In one example, the sensor includes a heat transfer transducer. In one variation, a portion of the heat transfer transducer is accessible from outside the housing and is positioned proximate to the outside of the housing. In another example, the sensor controller is configured to detect the presence of the first network and the presence of at least one additional network. In one variation, the sensor controller is configured to provide an analog output over the first connection when there is no first network and at least one additional network. In yet another example, the sensor device is a stand-alone leak detection device that is further positioned in the housing and includes at least a power source coupled to the sensor controller and an indicator visible from outside the housing. The indicator is configured to provide an indication of the presence of the tracer gas.

  In a further exemplary embodiment, a gas sensor device for detecting the presence of gas comprises a housing including a first outer surface and a sensor configured to detect the presence of gas and generate a sensing signal; The sensor includes a transducer portion that is positioned proximate to the first outer surface of the housing such that gas can contact the transducer portion, and the gas sensor device is connected to the sensor and is A sensor controller configured to generate an output signal based on the generated detection signal is provided, wherein at least a portion of the sensor and the sensor controller are housed in the housing. In one example, the gas sensor device further includes an I / O interface coupled to the housing and configured to connect the sensor controller to at least one device remote from the gas sensor device. In one variation, the output signal of the sensor controller is a scaled analog output signal representing the amount of gas detected by the sensor, and the scaled analog output signal is routed through the first connection of the I / O interface. Available on at least one remote device. In another variation, the output signal of the sensor controller is a digital signal representative of the amount of gas detected by the sensor, the digital signal via at least one remote device via a second connection of the I / O interface. It becomes available at. In yet another variation, the I / O interface further includes at least one transceiver configured to receive a digital signal from the sensor controller and generate and transmit a data packet including the digital signal. In another example, the gas sensor further comprises an indicator configured to provide a visible display signal, wherein the visible display signal indicates the presence of gas and the visible display signal can be viewed from outside the housing.

  In yet another exemplary embodiment, a sensor device for use in a network comprises a housing and a sensor configured to detect the presence of a tracer gas and generate a sensing signal, the sensor being a first sensing device. The first detection unit is positioned so that the tracer gas can come into contact with the first detection unit, and the sensor device is connected to the sensor and detects a detection signal generated by the sensor. Based on a sensor controller configured to generate an output signal and a network controller coupled to the sensor controller and configured to generate a network data packet, the network data packet being transmitted by the sensor controller Including information based on the generated output signal, and the sensor device further includes a network controller. Is connected to over La, a network interface suitable for connecting the sensor device to the network, the housing, at least a first portion of the sensor, the sensor controller, and configured to accommodate the network controller. In one example, the sensor includes a heat transfer transducer. In yet another example, the sensor device further comprises an indicator coupled to the sensor controller, wherein the indicator is configured to provide status information associated with the sensor device and the presence of the tracer gas. And a second indicator configured to provide an indication of

  Additional features of the present invention will become apparent to those skilled in the art from consideration of the following detailed description of the preferred embodiment, illustrating the best mode contemplated for carrying out the invention at the present time. .

  The present disclosure describes U.S. Patent Application No. 10 / 382,961 “Method and Apparatus for Detecting Gas” filed Mar. 6, 2003, and U.S. Patent Application No. 10 / 382,565 filed Mar. 6, 2003. The issue “Method and apparatus for detecting leaks” is expressly incorporated by reference.

  The detailed description of the exemplary embodiments particularly refers to the accompanying drawings.

  While the invention is susceptible to various modifications and alternative forms, exemplary embodiments thereof are shown by way of example in the drawings and are described in detail herein. However, there is no intention to limit the invention to the particular forms disclosed, but on the contrary, all modifications, equivalents, and alternatives are included within the spirit and scope of the invention as defined by the appended claims. It should be understood that it is intended to be covered.

<Leak detection device>
Referring to FIG. 1, a schematic diagram of a leak test apparatus 100 according to the present invention is illustrated. The leak test apparatus 100 includes a test area 120, a plurality of sensors 106 (of which sensors 106a and 106b are illustrated as an example), a controller 108, and an indicator 110. Although only two sensors 106a and 106b are shown in FIG. 1, the plurality of sensors 106 may include two, three, or more sensors. Test area 102 is configured to receive a part under test 112 having at least a first potential leakage area 114. Examples of potential leak areas include weld areas and joints. However, in one embodiment, the entire surface of the part under test or a portion thereof may be tested for potential leaks, and therefore the entire surface or portions thereof may be considered a potential leak region. In one example, the test area 102 is configured to hold a part under test 112 and is configured to position a plurality of sensors 106 relative to a potential leak area 114 of the part under test 112, at least Includes one fixture (not shown). In another embodiment, the test region 102 further includes a pressure chamber (not shown). The pressure chamber is configured to pressurize the air volume around the part under test 112.

  In the illustrated embodiment, the controller 108 includes a computer 116 and a programmable logic controller (PLC) 118. The computer 116 processes the data received from the plurality of sensors 106, identifies the leak location, provides a signal to the leak location indicator 110, and provides the ability to store the leak data for future analysis. Composed. In another embodiment, the computer 116 is further configured to quantify the leak rate of the leak and provide a signal to the leak rate indicator 110. An exemplary computer 116 is an EMAC industrial computer available from EMAC, Inc. located in P.O. Box 2042, Carbondale, IL 62902.

  The PLC 118 is configured to control the physical movement of the leak test apparatus 100. An exemplary PLC 118 is model number SLC 5/05 available from Allen Bradley via Rockwell Automation, US Bank Center, 777 East Wisconsin Avenue, Suite 1400 Milwaukee, Wisconsin 53202. In one example, the PLC 118 secures the part under test 112 in a corresponding fixture or group of fixtures configured to actuate a component, such as a cylinder, to secure the part under test 112, and a plurality of sensors. 106 a and 106 b are configured to be positioned proximate to potential leakage region 114. The PLC 118 is further configured to control the filling and exhausting of the tracer gas at the part under test 112. In an alternative embodiment, the PLC 118 is configured to control the filling and exhausting of the tracer gas in the pressure chamber of the test area 102. The use of PLCs, such as PLC 118, to control the filling and exhausting of tracer gas at the part under test is well known in the art.

  The PLC 118 is further connected to a human-machine interface (HMI) 119. The HMI 119 provides input parameters such as a set value or leak rate corresponding to an unacceptable leak in the part under test and / or a test timer value that controls the length of the test cycle of the part under test 112 to the operator of the leak test apparatus 100. An exemplary interface for input to the leak test apparatus 100 is provided. An exemplary HMI is the Panelview standard terminal obtained from Allen Bradley via Rockwell Automation located at US Bank Center, 777 East Wisconsin Avenue, Suite 1400 Milwaukee, Wisconsin 53202. In the illustrated embodiment, the HMI 119 is linked to the controller 108 via a network, such as the network 120 described below. In an alternative embodiment, the HMI 119 is connected directly to the controller 108.

  In another embodiment, the PLC 118 is provided with parameter values from a computer 116 or from a remote computer (not shown) via a network, such as the network 120. In a further embodiment, the PLC 118 is provided with parameter values from the PLC 118 or a computer readable medium (not shown) removably coupled to the computer 116 or a remote computer (not shown).

  In one embodiment of the leak test apparatus 100, the PLC 118 is further configured to perform an initial knockout or gross leak test on the part under test 112, such as a pressure drop test. It is well known in the art to perform a pressure drop test on a part under test using a PLC such as PLC 118. If the part 112 does not pass the gross leak test, the part under test 112 is tested with the more accurate tracer gas or fine leak test described below unless it is desired to accurately locate the gross leak. There is no need. In one variation, a gross leak test such as a pressure drop test is performed simultaneously with the fine leak test. When the pressure drop test and the fine leak test are performed simultaneously, the pressure drop test uses a gas containing a tracer gas.

  In the illustrated embodiment, computer 116 and PLC 118 are linked together via network 120. The network 120 is configured so that the computer 116 and the PLC 118 can share information. Exemplary networks include a wired network or a wireless network such as an RF network, an IR network, or a cellular network, a local area network such as an Ethernet network or token ring network, a wide area network, a controller area network (CAN), the Internet, or an intranet. Connection, RS232 connection, RS485 connection, or any other suitable network or method for connecting computer 116 and PLC 118. The computer 116 and PLC 118 can be connected to additional devices over the network 120, such as a remote computer (not shown) for quality control, or to a control device positioned at a station in the manufacturing process of the part under test 112. Thus, feedback can be immediately provided to quality control personnel or manufacturing personnel regarding leak locations in rejected parts or any correlation between leak locations of rejected parts.

  In an alternative embodiment, controller 108 comprises a single computer, such as computer 116, configured to perform the above functions of both computer 116 and PLC 118. In one example, the HMI 119 is a touch screen, light pen, mouse, roller ball, or keyboard.

  As described above, for the fine leak test, the controller 108 is configured to provide a gas including a tracer gas to the inside of the part under test 112 or the outside of the part under test 112. It is well known in the art to seal the device under test so that the tracer gas is held inside or outside the device under test 112 as long as the device under test 112 does not leak. When the tracer gas is provided inside the part under test, the test area 102 does not require a pressure chamber, whereas when the tracer gas is provided outside the part under test 102, the test area 102 is A pressure chamber (not shown) is included so that the outside of the part 112 can be pressurized.

  The tracer gas is introduced inside or outside the part under test 112 so that the inside or outside containing the tracer gas has a relatively high pressure relative to the other inside or outside that does not contain the tracer gas. Therefore, a pressure difference is formed between the inside of the part under test 112 and the outside of the part under test 112, and the high pressure region corresponds to a region containing the tracer gas. Therefore, when the part under test 112 includes a leak, the tracer gas flows out or flows from the high pressure region to the low pressure region. In one example, the tracer gas is helium. In another example, the tracer gas is hydrogen.

  The leak test apparatus 100 is configured to detect the presence of a leak in the part under test 112, as indicated by the presence of tracer gas in the low pressure region. The leak test apparatus 100 is further configured to perform a leak test, whereby the leak in the part under test 112 is monitored over a period corresponding to the value of the test timer provided by the PLC 118. As shown in FIG. 1, the sensor 106 is positioned proximate to the potential leak region 114. As described above, it is conceivable to position three or more sensors 106 close to the region 114. The sensor 106 is connected to the controller 108 and is configured to provide a sensing signal representative of the detection of tracer gas. In one example, the detection signal is proportional to the concentration of the tracer gas. In the illustrated embodiment, the sensors 106a and 106b are connected to the controller 108 via the network 122, the network 122 is generally similar to the network 120, and the sensors 106a and 106b generate sensing signals, respectively, The detection signal is provided to the controller 108 as a network message or data packet. In one example, network 122 and network 120 are part of the same network. In an alternative embodiment, the sensor 106 is directly connected to the controller 108, which receives the detection signal from each sensor as a direct input, such as an analog signal.

  The controller 108 is configured to receive a detection signal from the sensor 106 and determine whether the signal indicates that there is a leak in the part under test 112. As described in more detail below, the leak location can be estimated by monitoring individual detection signals from the sensor 106. Further, as described in detail below, when the sensor defines an area of confinement or accumulation volume, the leak rate of the leak can be estimated by monitoring a total detection signal, such as the detection signal from both sensors 106.

  The indicator 110 is connected to the controller 108 and is configured to provide an operator of the leak test apparatus 100 with an indication of the presence and location of leaks in the part under test 112. The controller 108 is configured to provide a leak detection signal to the indicator 110 in response to at least one of the sensors 106a and 106b detecting the presence of the tracer gas. Further, the leak detection signal of the controller 108 can be provided to other devices such as a remote controller (not shown). The leak detection signal includes information representing a leak location and / or information related to the leak rate of the leak.

  In the illustrated embodiment, the indicator 110 is directly connected to the controller 108. In another embodiment, indicator 110 is linked to controller 108 via a network, such as network 120. Examples of display signals include a signal to a network device that includes a leak location, a voice message, a visual text message of the leak location, or a visual image of a part under test with a leak graphic placed at the leak location. In one embodiment, indicator 110 is further configured to provide an indication of the leak rate of the leak. The leak rate indication can be included in the same signal as the leak location, or can be transmitted in a second display signal.

  Referring to FIG. 2, a leak test apparatus 100 'that is configured to monitor a part under test 212 having at least two potential leak regions 214a and 214b is illustrated. The leak test apparatus 100 ′ is generally similar to the leak test apparatus 100. For this reason, the same numerals are used for components common to the leak test apparatus 100 and the leak test apparatus 100 '. As shown in FIG. 2, a first sensor array 224a with a plurality of sensors, such as sensors 106a and 106b, is positioned proximate to the first potential leak region 214a and the sensors 206a, 206b, 206c. , 206d, 206e, 206f, and 206g, a second sensor array 224b with a plurality of sensors is disposed proximate to the second potential leak region 214b. Sensors 206a-206g are generally identical to sensors 106a and 106b. Each sensor array 224a and 224b is connected to the controller 108. As described above, the sensors are connected to the controller 108 via a network such as the network 122 or directly.

  In one embodiment, sensor arrays 224a and 224b simply refer to a collection of sensors 106a and 106 and sensors 206a to 206g, respectively. In another embodiment, sensor arrays 224a and 224b correspond to network devices configured to relay network traffic from their respective sensors to other network components such as controller 108. In one example, sensor arrays 224a and 224b are network routers. In yet another embodiment, sensor arrays 224a and 224b are controllers that receive data from each sensor and compile network messages to other network devices based on the data received from each sensor. Configured to do. In one example, each sensor is linked to a sensor array controller via a network similar to network 122. In another example, each sensor is directly connected to the sensor array controller and provides an analog output. The network message compiled by the sensor array controller may be a relay of signals from each sensor, a leak location indication, or a leak rate indication.

  The present invention may be implemented with a single sensor positioned proximate region 214a and a single sensor positioned proximate region 214b, but in proximity to potential leak region 214a or 214b. The more sensors that are positioned in this way, the more accurate the leak detection device 100 'will be in determining the leak position and / or quantifying the leak rate. Therefore, it is preferable to connect the sensors 206a to 206g, 106a and 106b to the controller 108 via the network, because such connection does not require the controller 108 to have a large number of data inputs. This is because only a large number of sensors can communicate with the controller 108.

  Referring to FIG. 3, the exemplary sensor array 130 includes a plurality of sensors 132a-132l. Sensor array 130 is configured for use with leak test apparatus 100 or leak test apparatus 100 '. As shown in FIG. 4a, each sensor 132a-132l includes a sensing element or transducer 134a-l. In a preferred embodiment, the sensors 132a-132l are configured to interface with a network such as a controller area network (CAN) or an RS-485 network. An exemplary sensor for use on a CAN network or RS-485 is the sensor 300 illustrated in FIGS. 14-24 below. As described below, in connection with sensor 300, sensing elements or transducers 134a-134l of sensors 132a-132l are adapted to detect the presence of tracer gas when tracer gas contacts sensing elements or transducers 134a-l. Consists of. While the sensor 300 as described below can function in both analog and network modes, the sensors 132a-132l in the preferred embodiment only need to be able to function in network mode, and in addition RS-485 or CAN. It is understood that it only needs to be configured for one network such as In an alternative embodiment, sensors 132a-132l are configured for more than one network.

  Sensors 132a through 132l of sensor array 130 are easily positioned relative to potential leakage areas of the part under test, such as weld 134 of torque converter 136 shown in FIGS. As shown in FIG. Fixture 133 positions sensor 132a-132l in proximity to weld 134 of torque converter 136 in a reproducible manner such that sensor 132a is always positioned adjacent portion 138 of weld 134. Configured. Therefore, in the first torque converter 136 and the subsequent torque converter 136, when there is a leak in the portion 138 of the welded portion 134, the sensor 132a that is the same sensor is close to the leak.

  As shown in FIGS. 3, 4 a, 4 b, 5, and 6, the fixture 133 is configured to cooperate with the part 134 to define an internal region or accumulation volume 140 (shown in FIG. 6) and welds Any discharge tracer gas from the interior region 142 of the part 136 is collected via a leak, such as leak 144 at 134. Emission tracer gas is collected in the interior region 140 so that changes in the tracer gas concentration over time can be monitored to quantify the leak rate of the leak. In one example, the inner region 142 is a closed region in order to prevent a pressure increase in the inner region 142 and a slowdown of the leak 144 due to a pressure increase that may lead to an incorrect calculation of the corresponding leak rate. Absent.

  In an alternative embodiment, a fixture for securing the sensor array supports the sensor and positions the sensor in a reproducible manner with respect to potential leakage areas. However, the fixture does not define an internal area where the discharged tracer gas collects. As such, the fixture does not allow accurate estimation of the leak rate and only displays the leak position relative to the potential leak area.

  Referring to FIG. 6, sensor 132f is positioned proximate to leak 144. FIG. Therefore, the sensing element 134f detects the presence of the tracer gas released from the leak 144 before the sensing element 134a of the sensor 132a. Furthermore, over time, sensor 132f will have a maximum response compared to sensor 132a, which means that sensor 132f detects a higher concentration of tracer gas than sensor 132a. One or both of these facts are used to determine the location of the leak 144, as will be described below. Further, as described below, when the shape of the fixture 133 is such that the tracer gas released from the leak 144 is generally retained in the inner region 140, the sum and average of the responses of all sensors 132a-132l. Is used to determine the leak rate associated with leak 144.

  With reference to FIGS. 7-10, an exemplary embodiment of leak testing software 600 is illustrated. The leak test software 600 is configured to be executed by the controller 108 in connection with the fine leak test. For example, for testing component 136 of FIGS. 3, 5, and 6, software 600 associates sensor array 130 and sensors 132a-132l with test component 136, and sensors 132a-132l via a network, such as network 122. Is configured to monitor the signal provided by and provide an indication of the location of the leak 144 and / or an indication of the leak rate associated with the leak 144. In one embodiment, the controller 108 provides an indication of the location of the leak 144 and / or the leak rate of the leak 144 as a leak detection signal. Software 600 may be configured to monitor multiple sensor arrays. In the exemplary embodiment shown in FIGS. 7-10, the leak test software 600 is executed by the computer 116 to send and receive information to and from the PLC 118. In an alternative embodiment, leak test software 600 is partially executed by computer 116 and partially executed by PLC 118. In a further alternative embodiment, at least some of the functions of the software 600 are provided as firmware. In another alternative embodiment, the software 600 is executed by a remote computer and the commands are provided to the controller 108 via a network, such as the network 120.

  In one embodiment, the software 600 is available as one or more files on a portable computer readable medium such as a diskette, CD-ROM, ZIP disk, tape, memory card, or flash memory card. Software 600 in one example includes an installation program configured to load software 600 to computer 116 and / or to set software 600. In an alternative embodiment, the software 600 and / or the installation program is available over the network as one or more download files.

  Referring to FIG. 7, the leak test software 600 includes a setup section configured to allow an operator to set various parameters associated with a particular job, such as testing a particular part under test, such as part 136. 602 and an operator portion 604 configured to be used by an operator preparing for part leak testing. The operator unit 604 is configured to load a parameter set for a particular part under test and execute a test routine 656 that tests for leakage of the first part.

  Referring to FIG. 8, an exemplary setup portion of software 600 is illustrated. As represented by block 606, at least a first picture representing the part under test is loaded. The picture is used to provide a visual indication of the leak location to the operator. In the first example, a picture corresponds to a still image of a physical part. In the second example, the picture corresponds to a view generated from an electronic database of parts, such as a CAD software package. In a third example, a picture corresponds to a three-dimensional solid model of a part generated from an electronic database such as a CAD software package.

  As represented by block 608, the operator places a representation of the sensor, such as sensor 132a, on the picture of the part under test. In one embodiment, the representation of a sensor is a sensor icon, see FIG. 13a for an example of a sensor icon such as sensor icon 135a. The sensor icon shown in FIG. 13 has a triangular shape. However, it is contemplated that the sensor icon can have a variety of shapes and can include text so that the sensor number and / or sensor name is displayed. The position of the sensor 132a on the picture corresponds to the position of the physical sensor 132a relative to the part 136 under test of the part 136. However, by updating the position of the sensor 132a on the picture, the position of the sensor 132a on the physical part does not move. The position of the sensor 132a on the picture is simply a representation of the position of the sensor 132a on the physical part. Next, the operator updates information about sensor 132a as represented by block 610. Examples of updated sensor information include the name of the sensor 132a, the network ID of the sensor 132a, sensor position data, to which sensor group or array 130 the sensor 132a is associated, and the currently displayed sensor 132a or picture Display priority. The display priority is a parameter associated with the preferred view that indicates the leakage that occurs from the sensor 132a. In the case of a picture, the display primary parameter indicates a default view used during the operator unit 604.

  Software 600 asks whether to display additional sensors on the current picture of the part under test, as represented by block 612b. If the position of the additional sensor is visible in the current picture, the operator selects yes and repeats the above process for the additional sensor. If the additional sensor is not visible in the current picture, the operator should select no so that the software 600 loads an additional picture of the part under test as represented by block 614. To ask questions. When loading additional pictures, the operator selects yes and the software 600 loops back to block 606. Otherwise, the operator is instructed to save a sensor mapping file corresponding to the part under test, as represented by block 616. The sensor mapping file includes information input during the setup unit 602. In one example, the sensor mapping file is a text file including at least a reference to a picture of a part under test, a sensor included on each picture, a sensor position for each picture, and a sensor parameter for each picture.

  Referring to FIG. 9, an operator unit 604 of software 600 is illustrated. As represented by block 620, when the operator activates the operator portion 604, the operator enters or selects a directory location that includes a sensor mapping file corresponding to the current part under test, such as part 136. If the operator does not select an appropriate path, the operator will need to enter or select the directory again, as represented by block 622. On the other hand, if an appropriate path has been selected, the operator then selects the correct sensor mapping file 616 as represented by block 624.

  The sensor mapping file is loaded into the memory of the controller 108 and, as represented by block 626, a list of pictures of the part under test contained in the sensor mapping file is presented to the operator. As represented by blocks 628 and 630, the operator selects a picture from the list, and the selected picture is displayed along with the sensor icon 135 on the corresponding display. By allowing the operator to select a picture to be displayed, visual inspection by the operator can be performed, and it is ensured that the selected sensor mapping file corresponds to the part to be tested.

  Here, the operator can change the sensor information or sensor placement, as represented by block 632, or can proceed to the start of the test. If an update is required, the operator selects the sensor to update as represented by block 634. The operator can update the arrangement of the selected sensor by manually inputting new position information or by moving the corresponding sensor icon 135 relative to the part picture. However, the user only changes the position of the sensor on the picture, not the actual physical sensor position. As represented by blocks 636, 638, and 640, a new sensor position is received in either manner and the sensor table is updated. Further, the operator can update sensor information such as display priority, sensor name, or sensor network ID, as represented by blocks 642, 644, and 646. In one example, the sensor information needs to be updated when a new sensor with a different network ID is replaced with a broken sensor.

  The operator can then select another sensor, as represented by block 648, and update the sensor position or sensor information associated with that sensor. If additional sensors are selected, the above process associated with blocks 636, 638, 640, 642, 644, and 646 is repeated. After making an update to the sensor location or sensor information, the operator needs to save the changes to the sensor mapping file, as represented by block 650, or discard the changes. When saving changes, as represented by blocks 652, 654, and 656, the software 600 asks if a test routine should be started. When discarding the changes, the operator is again presented with the option to update the sensor location or sensor information, as represented by block 632.

  After updates to the displayed picture have been made, as represented by blocks 654, 656, 658, 660, and 662, the operator can initiate a test routine as in block 656, as in block 660. It is possible to exit the program, select a new sensor mapping file as in blocks 662 and 620, or select additional pictures associated with the current sensor mapping file as in blocks 662, 626, and 628. is there. The operator, in one example, selects additional pictures associated with the sensor mapping file to update sensor placement or sensor information for sensors that are not visible in previously displayed pictures. Further, in one example, the software recognizes a change in sensor position or sensor information in the first picture and updates the corresponding sensor position or sensor information in an additional picture that includes the sensor.

  Referring to FIG. 10, an example test routine 656 is illustrated. As represented by blocks 664 and 665, when the test routine is initiated, the selected sensor mapping file is loaded at block 664 and an image or picture of the associated part is loaded at block 665. One of the component images has a parameter value that designates the component image as a default image. The default part image is displayed on the display as represented by block 668. The display of the default image provides the operator with a visual cue that the software 600 has loaded the correct sensor mapping file and the corresponding part image.

  Software 600 waits for a test start signal from the PLC indicating that the part under test is ready for testing, as represented by block 670. In one example, the signal from the PLC is such that the part under test 136 is properly positioned in the test area 102, the sensors 132 are all in the correct position, the tracer gas is properly introduced, and between the outside and inside of the part under test. Corresponds to the situation where the pressure difference is established. When a test start signal is received from PLC 118, a command to monitor the presence of tracer gas is issued to all sensors 132, as represented by block 672, and a test timer as represented by block 674. Is started. The test timer defines the test length of part 136. If no leak is detected in part 136 during the length of the test timer, part 136 is approved. In one example of a test routine 656, the test routine is reset upon detection of a leak or expiration of a test timer and begins testing the second part, which is typically the same as part 136. Thus, when the operator enters the test routine 656, the operator does not need to go through additional instructions of the operator unit 604 again, such as blocks 620, 624, and 628, before testing the second part.

  As represented by block 676, the software monitors the network 122 to determine if data has been received from a sensor 132 or other component on the network 122. If data is received via the network 122, a determination is made as to whether the data corresponds to detection of tracer gas, as represented by block 678. In one example, the determination depends on whether the amount of tracer gas detected exceeds a threshold set by a parameter in the sensor mapping file. If the data does not correspond to tracer gas detection, the test timer is checked to determine if the test procedure is complete, as represented by block 680. Examples of cases where the data does not correspond to the detection of tracer gas include sensor status data such as whether the sensor 132 is operating properly or an error has occurred.

  If the data corresponds to the detection of tracer gas, the data and subsequent data are analyzed, as represented by block 685. The data is analyzed to determine the leak location, as represented by block 686, a location routine. In one embodiment, the data is further analyzed to determine the rate of leak, as represented by block 688, which is a leak rate routine. Leak rate routine 688 is generally executed concurrently with position location routine 686. Both the locate routine 686 and the leak rate routine 688 display leaks in the part 136, such as visualization of leaks on a picture or image of the test part to allow the operator to easily recognize the leak location and size. Provides information to generate For example, a leak graphic 137 as illustrated in FIG. 13B that represents detection of leaks by the sensor 132f. Additional indications of leaks include visual signals such as signals sent by the controller 108 to a remote device such as a quality control or manufacturing area computer, visual text messages on the HMI unit associated with the PLC 118, alarm sounds, or flashing lights. Includes static queues.

  The locate routine 686 determines the leak location by finding the sensor that is detecting the highest concentration of tracer gas, as represented by block 690. The leak position is correlated to the position of this sensor, as represented by block 692. As represented by block 694, a picture of part 136 that provides an optimal representation of the leak location is automatically selected and displayed along with the leak location indication. The displayed picture is based on the display preference for the sensor in the sensor mapping file. In the first example, flashing the corresponding sensor icon or changing the color or other attribute of the corresponding sensor icon is a visual cue for the leak location. In the second example, as shown in FIG. 13B, the leak location is indicated by a leak graphic 137 representing the release of tracer gas from the leak location. In a further example, the leak graphic of FIG. 13B is an animation graphic, such that the graphic simulates gas flowing out of the leak location. In yet a further example, the leak graphic flashes to further indicate the leak location. An exemplary sensor icon and leak graphic are both illustrated in FIG. 13B.

  In an alternative embodiment, the leak location is determined by the sensor that first detected the tracer gas. In a further alternative embodiment, the leak location is determined by a sensor that first detects the presence of tracer gas above a threshold level. In yet a further alternative embodiment, two adjacent sensors both report similar detection of the tracer gas, and the leak location is determined by the relative weighting of the values reported by each sensor, between the sensors, or It is determined to be between two adjacent sensors, such as in the vicinity of the first sensor of adjacent sensors.

  In addition, it is believed that the part under test can have more than one leak. Multiple leaks can occur in the same potential leak region or in different potential leak regions. The location routine 686 and speed routine 688 described above are executed in each area when sensors in different potential leak areas each report a leak detection. If multiple leaks are present in the same potential leak area, the software recognizes multiple leaks by detecting tracer gas with two non-adjacent sensors that generate a leak condition. For example, two non-adjacent sensors each record the maximum of the tracer gas concentration, or two non-adjacent sensors each indicate the presence of the tracer gas before the intervening sensor records the presence of the tracer gas. Record.

  In the case of a large number of leaks, a large number of images of the part under test can be simultaneously displayed on the display, like a split screen. Multiple views of the part under test are required because the preferred view of each sensor can result in a different image, or at least one sensor corresponding to a leak is preferred for other sensors. This is because it is not visible in the image.

  The leak rate routine 688 is configured to determine the leak rate of the identified leak. As represented by block 696, for the sensor array that detected the leak, the readings from each sensor associated with that sensor array are added and then averaged. In addition, this average sensor reading is monitored over time and an average rate of change in the average sensor reading is calculated as represented by block 698. Under normal leak test conditions, the test cycle and leak size are such that the rate of change of the average sensor reading is generally linear. Therefore, the leak rate is approximated by determining the slope of the line that approximates the average sensor reading over time.

  The rate of change of the average sensor reading is normalized to the leak rate unit, as represented by block 700. In one example, the normalization compares the ramp rate determined by block 698 with a known leak ramp rate, taking into account the accumulated volume of the fixture that houses the sensor, such as fixture 133. To be achieved. The rate of change of the average sensor reading is directly proportional to the leak rate of the leak and inversely proportional to the amount of accumulated volume. In addition, the leak rate is displayed on the part picture or image along with the leak location determined by the locate routine 686. In one example, the leak rate is shown as a numerical value close to the leak location. In another example, the leak rate is simulated by selection of the leak graphic used to simulate the leak (see FIG. 13B). For example, a graphic showing a large leak out of the leak location is used for a high leak rate, and a graphic showing a small leak out of the leak location is used for a low leak rate.

  Referring to FIGS. 11 and 12, an example of sensor output corresponding to a leak test of a part 136 by the leak test apparatus 100 is shown. In the example shown in FIGS. 11 and 12, a known leak 144 has been brought into the part in the vicinity of the potential leak area 134. A known leak 144 was formed in part 136 by inserting a calibration leak reference into part 136. Furthermore, the known leak 144 was sized with a known leak rate equal to 0.1 scc / min (standard cubic centimeter per minute). To test the leak test software 600, tracer gas was provided to the interior 142 of the part 134 via a valve so that the response time of the system 100 could be determined.

  FIG. 11 presents individual sensor readings over time of five of the 16 sensors positioned in proximity to the potential leak area. The five selected sensors correspond to the four sensors closest to leak 144 and the one sensor far from leak 144. Note that the 16 sensors exceed the 12 sensors 132a-132l illustrated in FIGS. Thus, the results shown in FIG. 11 should be able to provide a more accurate leak 144 location than the results of the twelve sensor arrangements shown in FIGS.

  Referring to FIG. 11, the sensor shown as sensor 13 shows the first detection of the tracer gas and the highest recorded concentration of the tracer gas, as represented by the data series 160. Sensors shown as sensors 12, 14, and 15 are proximate to sensor 13 and are represented by data series 162, 164, and 166, respectively. Each of the sensors 12, 14, and 15 detects the presence of the tracer gas slightly after the sensor 13, and each of the sensors 12, 14, and 15 detects a lower tracer gas concentration than the sensor 13. Therefore, the position of the leak 144 is close to the sensor 13. However, it should be noted that the strong response of sensor 14 and the similar response of sensors 12 and 15 suggest that the leak is located approximately halfway between sensors 13 and 14. Further, the data series 168 corresponding to the sensor shown as sensor 5 positioned distal to sensor 13 is similar to that of leak 144 as compared to sensors closer to leak 144, such as sensors 12, 14, and 15. A sensor far from the location is included to indicate that the tracer gas detection and the tracer gas measured concentration fall behind.

  Referring to FIG. 12, two types of data series 170 and 172 are illustrated. Data series 170 corresponds to the start of leak 144 represented by portion 174 of series 170 and the stop of leak 144 represented by portion 176 of series 170. Leakage 144 is initiated by introducing tracer gas into the interior 142 of the part 136 through the valve and stopped by closing the valve. The data series 172 corresponds to the average value of the tracer gas concentration over time for all sensors in the sensor array. Looking at FIG. 12, the response time of the system is very good. The linear region 180 of the data series 172 occurs within about 3 seconds, suggesting that the system can determine the leak rate within about 3 to 5 seconds for leaks of known leak 144 size. Further, region 180 of series 172 is very linear, suggesting that the slope of region 180 provides a good approximation of the leak rate of leak 144.

  Referring to FIG. 10, the test timer overrides the location routine 686 and speed routine 688. Thus, when the test timer expires, a stop command is issued to the sensor, as represented by block 682. Further, as represented by block 684, the final leak rate is calculated and transmitted to the PLC. Alternatively, the final leak rate is made available by additional devices on the network 122.

<Sensor device for gas detection>
Referring to FIG. 14, a sensor device 300 is illustrated. Sensor device 300 is configured to detect the presence of a gas, such as a tracer gas, and provide an appropriate output to communicate the detection of the presence of the gas. In a first application, the sensor device is configured to detect the presence of a tracer gas such as helium or hydrogen in leak testing applications. In a second application, the sensor device 300 is configured to detect the presence of a tracer gas, such as helium or hydrogen, and be incorporated into a component design as a safety sensor, examples of components being automobiles, trucks, and the like. Aircraft, boats and their subsystems, such as fuel systems, exhaust systems, cabin systems, and cargo systems.

  In one example, the sensor device 300 can detect the concentration of helium, which is a tracer gas, in a range of about 0 ppm (parts per million) to about 5000 ppm, and has a resolution of about 25 ppm. In another example, the sensor device 300 can detect the concentration of helium, which is a tracer gas, in the range of about 0 ppm to about 5000 ppm and has a resolution of about 5 ppm. In yet another example, the sensor device 300 can detect helium concentrations greater than about 5000 ppm.

  The sensor device 300 can operate in one of two types of operation modes. In the first operation mode, the sensor device 300 is a self-contained sensor or a self-contained leak test device, and provides an operator with an indication of detection of gas such as tracer gas by the sensor device 300. In the second mode of operation, the sensor device 300 provides a signal to the remote controller, and the signal includes information related to detection of a gas, such as a tracer gas, by the sensor device 300. Both modes of operation are described in detail below. In an example of the second operation mode, the sensor device 300 is a network compatible sensor that provides a signal to a remote controller via a network.

  Sensor device 300 is a dual mode sensor device or a dual mode leak detection device when sensor device 300 is capable of operating in both modes of operation, even though not necessarily both modes simultaneously. However, as generally referred to in the sensor device 300 ′ of FIG. 15, it operates only in the first mode of operation, or as generally referenced in the sensor device 300 ″ of FIG. It is within the scope of the present invention to configure the sensor device 300 to operate only in the second operation mode.

  Referring again to FIG. 14, the sensor device 300 is a dual mode leak detection device and includes a controller 302, a power supply 306, an indicator 308, and an I / O interface 310 connected to the sensor 304 directly or via additional components. With. Controller 302, sensor 304, power supply 306, and indicator 308 are housed in housing 312. However, the indicator 308 is at least viewable from outside the housing 312 and the I / O interface 310 is accessible from outside the housing 312. Further, the sensing element or transducer 314 of the sensor 304 is accessible from outside the housing 312 and is generally positioned proximate to the outside of the housing 312. Thus, in the sensor device 300, the gas to be tested for the presence of the tracer gas need not be drawn into or passed through the internal sensing element.

  As described in more detail below, the sensor 304 is configured to detect the presence of a gas, such as a tracer gas, and provide a sensing signal to the controller 302, the sensing signal being the presence of the tracer gas or It indicates the lack and the amount or magnitude of the tracer gas detected. In one example, the detection signal is proportional to the concentration of the detected tracer gas. The power supply 306 is configured to provide power to the controller 302, sensor 304, indicator 308, and I / O interface 310. Indicator 308 is configured to provide an operator of sensor device 300 with detection of tracer gas and / or an indication of the amount of detected tracer gas. The I / O interface 310 is configured to provide an output signal to an external device, the output signal representing the detection or lack of detection of tracer gas and / or the amount of tracer gas detected. Further signals such as error signals or sensor status signals are also conceivable. In one embodiment, the I / O interface 310 is configured to link the sensor device 300 to a network.

  The controller 302 is configured to receive a detection signal from the sensor 304 and make an analysis or additional determination based on the detection signal from the sensor 304. Further, the controller 302 is configured to provide a display signal to the indicator 308, wherein the display signal represents the detection or lack of detection of the tracer gas and / or the amount of tracer gas detected, or the controller 302 Configured to provide an I / O signal to the I / O interface 310, wherein the I / O signal represents the detection or lack of detection of tracer gas and / or the amount of detected tracer gas or controller 302 is configured to provide both a display signal to indicator 308 and an I / O signal to I / O interface 310.

  Referring to FIG. 15, a sensor device 300 'is illustrated. The sensor device 300 'is generally similar to the sensor device 300 when the sensor device 300 is configured to operate in the second operation mode. Therefore, similar numbers are used for components common to both the sensor device 300 and the sensor device 300 '. The sensor device 300 'provides a signal to a remote controller (not shown), which includes information related to the detection of gas by the sensor device 300'. In one example, the sensor device 300 'is configured to be linked to a network. Thus, the sensor device 300 ′ is generally similar to the sensor device 300 except that an indicator such as the indicator 308 is not required. In addition, since the sensor device 300 ′ is connected to the remote controller via the I / O interface 310, the power required by the controller 302 and the sensor 304 is provided via the I / O interface 310 instead of the power supply 306. it can. Alternatively, the power source 306 is included in the sensor device 300 'in situations where a remote power source is not available, such as in a wireless network. Further, the electronic device of the sensor device 300 ′ is generally similar to the electronic device of the sensor device 300, but at least the sensor 300 ′ does not need to supply an analog output, does not need to control an indicator, and needs to control a power source. It may be simpler because of the fact that there is no.

  Referring to FIG. 16, a sensor device 300 '' is illustrated. The sensor device 300 '' is generally configured to operate in a first mode of operation corresponding to a self-contained sensor device that provides an indication of tracer gas detection by the sensor device 300 to an operator. This is the same as the sensor device 300 at the time. Therefore, the same numerals are used for components common to both the sensor device 300 and the sensor device 300 ″. The sensor device 300 ″ is generally similar to the sensor device 300 except that an I / O interface such as the I / O interface 310 is not required. Further, the electronic device of the sensor device 300 ′ is generally similar to the electronic device of the sensor device 300, but does not require at least an I / O interface, and the sensor does not need to configure data and information to be transmitted via the network. Because of this fact, it may be simpler.

  Referring to FIG. 17, one embodiment of a dual mode sensor device 450 is illustrated. The sensor device 450 is generally similar to the sensor device 300 and includes a controller 452, a sensor 454, a power source 456, an indicator 458, and an I / O member or interface 460, each generally in the controller of the sensor device 300. Similar to 302, sensor 304, power supply 306, indicator 308, and I / O member or interface 310. The sensor device 450 further comprises a programming input 462, which includes a series of inputs 464, and for modifying the configuration of the controller 452 or parameter values stored or accessed by the controller 452. Is configured to provide a programming signal. In one example, programming unit 452 is used to modify the network ID assigned to sensor device 450 for use in a CAN network.

  The sensor 454 of the sensor device 450 includes a heat transfer sensor 466 and an associated sensor circuit 468 that includes an amplifier circuit 470. The thermal conductivity sensor 466 includes a sensing element or transducer 467 (shown in FIG. 18) such as a membrane (not shown) that is heated above ambient temperature, a measuring resistor or series of resistors 472 that measure the temperature of the membrane, And an ambient temperature reference resistor or series of resistors 474 to compensate for temperature changes. As shown in FIG. 18, sensing element or transducer 467 is positioned external to sensor 466. In the illustrated embodiment, the thermal conductivity sensor 466 is model number MTCS-2202 available from Microsens SA, Rue Jaquet-Droz 1, CH-2007 Neuchatel, Switzerland. Alternative sensors include other suitable heat transfer sensors, sonic transducers, optical feedback transducers, and other suitable sensors that can detect the presence of tracer gas.

  The thermal conductivity sensor 466 measures the presence or concentration of the tracer gas by comparing the resistance of the measurement resistor 472, which is a measure of the temperature of the film, with the resistance of the reference resistor 474. A gas having a lower thermal conductivity than air changes the resistance of the measuring resistor 472 in order to change the surface temperature of the sensor film. Therefore, when the tracer gas is helium or hydrogen, the presence of helium or hydrogen adjacent to the sensor film changes the surface temperature of the sensor film and thus changes the resistance of the measuring resistor 472. Furthermore, as the concentration of helium or hydrogen adjacent to the sensor film increases, the resistance of the measuring resistor 472 further changes.

  An exemplary sensor circuit 468 including amplifier 470 is recommended by Microsens SA, manufacturer of heat transfer sensor 366. In alternative embodiments, variations of the sensor circuit are possible. The output of amplifier 470 corresponds to the sense signal of sensor 454 and is provided to controller 452 via connection 473. In one example, the detection signal is proportional to the concentration of the detected tracer gas. The voltage value at the output of the amplifier 470 directly depends on the resistance of the measuring resistor 472. Therefore, the detection of helium or hydrogen by the measuring resistor 472 causes the output voltage of the amplifier 470 to decrease.

  The power supply 456 includes a power supply 474 represented by designation of “5VDC” and a voltage regulator 476. Note that the designation of “5 VDC” has been illustrated many times in FIG. 17 for convenience and each case represents a connection to a power source 474. In one embodiment, the power source 474 is a portable power source such as a battery. The power supply 474, in another exemplary embodiment, is an external power source such as the output of an AC adapter connected to a standard outlet. Furthermore, a power supply 474, in yet another embodiment, is an external power supply that provides power to the sensor device 450 via the I / O interface 460.

  Voltage regulator 476 is configured to provide a generally constant voltage source for sensor 454 and controller 452. In the illustrated embodiment, voltage regulator 476 includes circuit chip 477 model number ADR421, available from Analog Devices, One Technology Way, P.O. Box 9106, Norwood, MA 02062-9106.

  Controller 452 includes, in the illustrated embodiment, Micro Converter® model number AduC834, available from Analog Devices. The controller 452 is a programmable device and includes a program memory (not shown) and a data memory (not shown). In the present invention, the controller 452 receives the detection signal from the sensor 454 via the connection 473 and analyzes and / or further detects the detection signal based on the detection signal and a command or program stored in the controller 452. Configured to make a decision. In one example, the controller 452 digitizes the detection signal from the sensor 454 and scales the detection signal to generate an output signal that is provided to the I / O interface 460. In one example, the output signal is an analog signal generated by a digital-to-analog converter (D / A). In another example, the output signal is a digital signal. Further, in one example, controller 452 generates a display signal that is provided to indicator 458.

  Indicator 458 comprises a first light emitting diode (“LED”) 478 and a second LED 480 in the illustrated embodiment. The LED 478 provides light having a first color such as green that is visible from the outside of the sensor device 450. The green light of LED 478 is provided in response to receiving a first display signal from controller 452 corresponding to the power-on state of sensor device 450. Thus, LED 478 provides a visual cue to sensor device 450 operator that sensor device 450 is receiving power and is capable of functioning. In an alternative embodiment, the first LED is controlled by the controller and flashes during the sensor device warm-up period to provide a stable signal when the sensor device is ready for testing.

  The LED 480 provides light having a second color such as red that is visible from the outside of the sensor device 450. The red light of LED 480 is provided in response to receiving a second display signal from controller 452 corresponding to detection of the presence of tracer gas by sensor device 450. Thus, LED 480 provides a visual cue to the operator of sensor device 450 that tracer gas has been detected. In a leak test application, LED 480 provides the operator with a visual cue that the part under test has a leak in the vicinity of sensor 454. In another example, LED 480 is a bicolor LED such as model number 591-3001-013 available from Dialight Corporation, 1501 Route 34 South Farmingdale, NJ 07727. The wavelength emitted by the bi-color LED 480 depends on the signal provided to the LED 480. For example, the wavelength can vary from a generally green wavelength to various orange, generally orange, and more generally red wavelengths. Thus, in one example, the bi-color LED 480 provides a visual cue of the detected tracer gas concentration to the operator of the sensor device 450 (from low density green to high density red). In another example, the bi-color LED 480 emits a green wavelength for low concentrations and a red wavelength for concentrations above the threshold. In an alternative embodiment, the second LED is controlled by the controller and flashes during a test period in the leak test application of the sensor device, providing a stable signal when the presence of tracer gas is detected by the sensor, and the tracer No light is emitted when the test period is completed without detecting gas.

  With reference to FIGS. 19 and 20, an exemplary embodiment of a sensor device 450 is illustrated, including a housing 496. Housing 496 is configured to enclose controller 452, sensor 454, power source 456 (if included), and indicator 458. Further, the housing 496 is configured to enclose a member 460, such as a CAN transceiver 492, a CAN controller 494, and an RS-485 transceiver 490. However, as shown in FIG. 19, the sensing element or transducer 467 of the heat transfer sensor 466 is accessible from the exterior of the housing 496 and is generally positioned proximate to the exterior of the housing 496. Further, as shown in FIG. 20, indicator 458 is at least viewable from the exterior of housing 496.

  As shown in FIGS. 19 and 20, the first portion 497 of the housing 496 causes the housing 496 to couple to another component, such as the fixture 133 shown in FIG. 3, in connection with a leak test application. Consists of. In the illustrated embodiment, the first portion 497 is threaded such that the first portion 497 can be screwed into a threaded opening (not shown). Nut 498 is shown screwed into first portion 497. Nut 498 helps to control the degree of engagement between first portion 497 and a threaded opening (not shown). The second portion 499 of the housing 496 is configured to be coupled by a tool. In the illustrated embodiment, the second portion 499 can be gripped by a wrench to assist in the engagement or separation of the first portion 497 and the threaded opening. A facet is formed.

  Referring again to FIG. 17, the I / O interface 460 is configured to provide one of three types of outputs to an external device in the illustrated embodiment. First, I / O interface 460 is configured to provide an analog output via connection 482 coupled to controller 452 through connection 484. In one exemplary embodiment, the controller 452 provides an analog signal scaled from 0 to 2.5 volts that represents the sensed signal from the sensor 454.

  Second, the I / O interface 460 is configured to provide RS-485 network compatible signals over connections 486 and 488. The I / O interface 460 includes a suitable transceiver 490 configured to comply with the RS-485 standard and communicates over the network with other devices configured to comply with the RS-485 standard. RS-485 transceiver 490 is controlled by controller 452 via various connections. RS-485 transceiver 490 is model number ADM485 available from Analog Devices in the illustrated embodiment.

  Third, the I / O interface is configured to provide CAN network compatible signals via connections 486 and 488 or additional connections. The I / O interface includes a suitable CAN transceiver 492 configured to conform to the CAN standard, and a suitable network such as a CAN controller and a CAN controller 494 configured to connect the controller 452 and the CAN transceiver 492. Communicate with other devices configured to be CAN-compliant, investigated by the controller. The CAN transceiver 492 is controlled by the CAN transceiver 494, which is controlled by the controller 452 via various connections with the controller 452. CAN transceiver 492 is model number MCP2551 and CAN transceiver 494 is model number MCP2510 in the illustrated embodiment, both from Microchip Technology, Inc., 2355 West Chandler Blvd., Chandler, AZ 85224-6199. It is available.

  The choice of analog, RS-485, or CAN output type to transmit the output signal is under the control of the controller 452. In a preferred embodiment, the controller 452 of the sensor device 450 is programmable to have plug-and-play functionality, and the controller 452 can connect any type of network to the sensor device 450, including the lack of a network. You will be able to recognize. The operation of the plug and play function and the additional function of the controller 302 will be described with reference to FIGS. 21 to 24 below.

  Referring to FIG. 21, a flowchart of exemplary software 500 configured to provide plug and play functionality to the controller 302 and configured to configure the controller 302 for leak testing applications is illustrated. . The software 500 delays further tasks until a function performed during the reset of the sensor device 450 or until it is determined that the sensor 454 is warmed up and ready to detect air around the sensor device 450. A power on or reset routine 502 corresponding to the function to be performed. Furthermore, the configuration steps 504 and 506 constitute the sensor device 450. The configuration step 504 configures the controller 452 including loading setup control parameters such as network addresses and sensor constants. Configuration step 506 configures CAN controller 494.

  After configuring the sensor device 450, the software 500 determines whether a network is currently connected to the sensor device 450, as represented by block 508. If no network is detected, software 500 allows controller 452 to generate an analog output via a D / A converter, as represented by block 510. The analog output is then available via connection 482 as described above. In addition, software 500 enables loop 511, as represented by block 512, in which analog data from sensor 454 is converted to digital data by controller 452 and then recovered to analog data by controller 452. , Allowing access to analog data via connection 482. In one example, the analog data generated by the controller 452 is different from the analog data received from the sensor 454 due to data scaling.

  Loop 511 reads analog data from sensor 454 via an A / D converter, as represented by block 514, processes and scales the received data as represented by block 516, and is represented by block 518. As such, if the resulting data is present, it is sent to the D / A converter to allow access to the data via connection 482. In one example, the controller 452 processes the data, determines if the data corresponds to detection of a threshold concentration of tracer gas, and generates appropriate instructions for the I / O member 460 and indicator 458. The threshold concentration or value, in one example, is programmed into the sensor controller 452. In another example, the threshold is communicated to the sensor controller 452 from a remote device.

  As loop 511 is executed, software 500 monitors potential network activity indicating that the network is connected to I / O member 460, as represented by block 520. If no network activity is detected, loop 511 continues. However, if network activity is detected, the D / A output (analog output) is interrupted as represented by block 522 to determine if a valid network is connected as represented by block 508. To do this, network activity is tested. If the activity is not a valid network, the D / A output is re-enabled and loop 511 is resumed, as in block 512.

  Assuming that a valid network has been detected, software 500 determines whether the test run flag has been set, as represented by block 524. The test run flag indicates that the controller 452 or a device via the network such as the PLC 118 or the computer 116 indicates that the leak test application has been started. Typically, leak test applications are run in specific time frames. Therefore, the sensor device 450 is configured to provide detection data, such as a detection signal, during the time frame of the leak test application.

  Assuming the test run flag has been set, as represented by block 526, the software 500 checks to see if the A / D result is ready. The A / D result corresponds to a digital signal representing the output of the sensor 454. In one example, controller 452 is configured to retrieve readings from sensor 454 at discrete time intervals, such as approximately every 100 ms. The value corresponding to the reading is stored in a memory accessible by the controller 452 in one example. Therefore, the software 500 checks whether the current value is stored in the memory. If the current value is not stored, software 500 waits for the current value unless it is necessary to perform an interrupt or other function, such as checking on-board diagnostics, as represented by block 528. An example of a type of on-board diagnostic is to check for sensor failure, as represented by block 530. If a sensor failure is detected, software 500 generates an error packet, as represented by block 532, and sends it over the network to other devices such as PLC 118 or computer 116.

  If the current value is stored in memory, software 500 erases the current result from the memory as represented by block 534 and the current result from the memory as represented by block 536. Generate and send a data packet containing it. Data packets are transmitted over the network to other devices such as PLC 118 or computer 116.

  Although software 500 is generally described in a gradual form, it is not limited to gradual execution. In one embodiment, software 500 checks for interrupt routines, parameter or flag changes, or the presence or absence of network activity at periodic time intervals. A first interrupt routine example 550 is illustrated in FIG. The interrupt routine 550 corresponds to the reception of a network message via a network such as a CAN network. The network message includes commands directed to the sensor device 450 and is configured to request or command the sensor device to perform a function. Software 500 is configured to interpret the transmitted command as represented by block 552.

  Four exemplary command types are illustrated in FIG. First, the test command type corresponds to a command directed to starting or suspending the test period, or an additional command associated with the test period, as represented by block 554. The first command example corresponds to a test start command, as represented by block 562. In response, software 500 sets a test run flag, as represented by block 564, to indicate that the test period has begun. The second command example corresponds to a stop test command, as represented by block 566, and in response, software 500 clears the test run flag, as represented by block 568, and Indicates that the test period has ended.

  Second, the data update command type corresponds to a command requesting data update or verification from the sensor device, as represented by block 556. An example of a first command to update and verify data is represented by block 570. In response, software 500 generates and sends a response with the requested data, as represented by block 572.

  Third, the data read command type corresponds to a command requesting reading and transmission of data stored in the memory of the sensor device, as represented by block 558. An example of a first command for reading data from memory is represented by block 574. In response, software 500 generates and transmits a response with the retrieved data, as represented by block 576.

  Fourth, the sensor update command type, as represented by block 560, corresponds to a command that requests the value of the current sensor device parameter or updates the sensor device parameter. An example of a first command that provides a new parameter value to the sensor device 450 is represented by block 578. In response, software 500 generates and transmits a response indicating that the parameter value has changed, as represented by block 580.

  A second interrupt routine example 582 is illustrated in FIG. Interrupt routine 582 corresponds to a watchdog service routine. The watchdog service routine determines whether a RESET command has been received, as represented by block 584, and generates a RESET for sensor device 450, as represented by block 586. In one example, the RESET command is received over the network. In another example, a RESET command is received by an operator pressing a RESET button (not shown) located outside the sensor device 450 or otherwise initiating a RESET command. In yet another example, the RESET command is generated by the controller itself, which means that the controller has become unstable or has become locked.

  A third interrupt routine example 588 is illustrated in FIG. The interrupt routine 588 corresponds to the A / D result preparation routine. As described with reference to FIG. 21, the software 500 monitors whether the A / D result is prepared corresponding to the data value from the sensor 454. Interrupt routine 588 is one of the mechanisms by which software 500 determines that a data value corresponding to sensor 454 is available. Interrupt routine 588 includes reading the A / D value, as represented by block 590, and setting the A / D result ready flag, as represented by block 592, to prepare for the new data value. Including notifying software 500 that it is ready.

  In one embodiment of the sensor device 450, all or substantially all of the electronics of the sensor device 450 includes a sensor controller 452, an I / O member 460 that includes corresponding electronics for at least one network type, and a sensor. In order to reduce the overall size of the sensor device 450, including 454, all are designed to be incorporated into a custom chip (not shown). In one example, the thermal conductivity sensor 466 is coupled to the surface of a custom chip (not shown) that includes all or substantially all electronics. In another example, the thermal conduction sensor is configured as a component of a custom chip (not shown), and the sensing element or transducer of the thermal conduction sensor is positioned outside the chip or accessible from outside the chip. Become. By making various connections with the leads of the custom chip, a network such as a CAN network or RS-485 can be connected to the custom chip. Along with the superior sensing capabilities of sensor device 450, the reduced size of sensor device 450 makes sensor device 450 ideal for incorporation into components such as automobiles as safety sensors. The sensor device 450 shares information with a component controller (not shown) and relays information and data regarding the presence or amount of gas.

  In another embodiment, the sensor device 450 is configured to operate in a second mode of operation similar to the sensor device 300 ′ of FIG. 15, and a custom chip (to reduce the overall size of the sensor device 450). (Not shown). Thus, the sensor device 450 does not include an indicator such as the indicator 458. In addition, since the sensor device 450 is connected to the remote controller via the I / O member 460, at least the power required by the controller 452 and the sensor 454 is transmitted via the I / O interface 460, not via the power source 476. Can be provided through. In one example, the thermal conductivity sensor 466 is coupled to the surface of a custom chip (not shown) that includes all or substantially all electronics. In another example, the heat transfer sensor is configured as a component of a custom chip (not shown), and the sensing element or transducer of the heat transfer sensor is positioned outside the chip or accessible from the outside of the chip. Become. By making various connections with the leads of the custom chip, a network such as a CAN network or RS-485 can be connected to the custom chip. As described above, the size reduction of the sensor device 450 together with the excellent detection capability of the sensor device 450 makes the sensor device 450 ideal as a safety sensor to be incorporated in a component such as an automobile. The sensor device 450 shares information with a component controller (not shown) and relays information and data regarding the presence or amount of gas.

  With reference to FIGS. 25 and 26, an exemplary embodiment of a sensor device is illustrated in which all or substantially all of the electronics of the sensor device 450 are incorporated into a custom chip. Sensor device 450 includes a housing 596 that is configured to encapsulate a custom chip (not shown) and sensor 454. Further, the housing 596 is configured to enclose a portion of an I / O interface 460, such as a CAN transceiver 492, and a CAN controller 494 that may be incorporated into a custom chip (not shown). However, as shown in FIG. 25, the sensing element or transducer 467 of the heat transfer sensor 466 is accessible from outside the housing 596 and is generally positioned proximate to the outside of the housing 596. Further, as shown in FIG. 26, the I / O interface 460 can be accessed from the outside of the housing 596.

  As shown in FIGS. 25 and 26, the first portion 597 of the housing 596 is configured to couple the housing 596 to another component. As shown in FIG. 27, the sensor device 450 is positioned at several locations on a component 700, such as an automobile. Sensor devices 450a and 450b are coupled to a fuel system 702 of the automobile 700, and sensor device 450c is coupled to an exhaust system 704 of the automobile 700. The sensor devices 450a, 450b, and 450c are connected to the component controller 706 of the automobile 700 via the I / O interfaces 460a, 460b, and 460c.

  While the invention has been described in detail with reference to specific exemplary embodiments, modifications are within the scope and spirit of the invention as defined by the appended claims.

1 is a schematic view of a leak test apparatus of the present invention configured to test for leaks in a part under test having a first potential leak region. FIG. FIG. 2 is a schematic diagram of the leak test apparatus of FIG. 1 configured to test for leaks in a part under test having at least first and second potential leak regions. 1 is a perspective view of a sensor array comprising a plurality of sensors and a fixture for attaching the plurality of sensors, wherein the plurality of sensors are positioned adjacent to a part under test having a first potential leakage region, It is a torque converter, and is a perspective view in which a first potential leak region is a welded joint. FIG. 4 is a bottom view of the sensor array and fixture of FIG. 3 showing respective sensing elements of a plurality of sensors. FIG. 4 is a perspective view of the sensor array and fixture of FIG. 3. FIG. 4 is a perspective view of the sensor array, fixture, and part under test of FIG. 3 showing the sensor array and fixture adjacent to the part under test. FIG. 6 is a cross-sectional view of FIG. 5 along line 6-6 showing the positioning of the first and second sensors in the sensor array relative to the first potential leakage area. 2 is a flowchart of a first exemplary embodiment of a leak test software, wherein the leak test software has a set-up portion and an operator portion. FIG. 8 is a flowchart illustrating a first exemplary embodiment of a setup portion of the leak test software of FIG. 8 is a flow chart illustrating a first exemplary embodiment of an operator portion of the leak detection software of FIG. 10 is a flowchart of a first exemplary embodiment of a test routine for an operator portion of the leak test software illustrated in FIG. FIG. 4 is a diagram of experimental data related to a first exemplary leak test showing five output data of the 16 sensors used in the leak test with the experimental sensor output of the leak test apparatus of the present invention. FIG. 5 is a diagram showing sensor output data of sensors in a leak test apparatus showing a linear relationship of the average concentration of tracer gas measured by all sensors in the sensor array as a function of time. It is a figure which shows the example of the several sensor icon superimposed on the picture of the to-be-tested part. FIG. 14 illustrates the sensor icon of FIG. 13 and an example of a leak graphic overlaid on a picture of a part under test, providing a visual cue for leaks originating from the part under test at the location of the leak graphic. FIG. 2 is a schematic diagram of a dual mode sensor device configured to detect the presence of tracer gas. FIG. 3 is a schematic diagram of a sensor device configured to detect the presence of a tracer gas and provide an output signal to a remote device. Schematic diagram of a sensor device configured to be a stand-alone leak detector It is a circuit diagram which shows the dual mode sensor apparatus of this invention. FIG. 18 is a perspective view of a heat transfer sensing element for use in a sensor device such as the sensor device of FIGS. It is the 1st perspective view of the exterior of the sensor apparatus of FIG. 17 incorporating the heat conduction sensor of FIG. FIG. 18 is a second perspective view of the outside of the sensor device of FIG. 17 showing the indicator and the I / O interface. 2 is a flowchart of a first exemplary embodiment of sensor software for a sensor device. FIG. 22 is a flowchart of a first exemplary interrupt routine of the sensor software of FIG. 21. FIG. 22 is a flowchart of a second exemplary interrupt routine of the sensor software of FIG. 21. FIG. 22 is a flowchart of a third exemplary interrupt routine of the sensor software of FIG. 21. FIG. 3 is a first perspective view of the exterior of the sensor device showing the sensing element accessible from the outside. FIG. 26 is a second perspective view external to the sensor device of FIG. 25 showing the I / O interface. It is a schematic diagram of the sensor device of the present invention incorporated as a sensor in a component such as an automobile.

Claims (54)

An apparatus for detecting the presence of at least one leak in a first region of a part under test and identifying the at least one leak location, wherein the first side of the first region includes a tracer gas and In a device that is at a higher pressure than the second side of the first region and the tracer gas flows out of the first side to the second side via the at least one leak,
A plurality of sensors positioned proximate to the first region, each configured to detect the presence of tracer gas flowing out of the leak and transmit a detection signal; and
A controller connected to the plurality of sensors and configured to transmit a leak detection signal in response to detecting at least a first sensor of the plurality of sensors detecting the presence of the tracer gas; A detection signal including leakage detection information representing the leakage position in the first region based on the detection signal received from at least the first sensor and the second sensor of the plurality of sensors;
A device comprising:   The apparatus of claim 1, further comprising an indicator configured to provide a visual indication of the leak location.   The indicator includes a display configured to display a first representation of the part under test and a sensor icon positioned on the first representation, the sensor icon being proximate to the leak location. The apparatus of claim 2, corresponding to the position of the first sensor.   The apparatus of claim 3, wherein the sensor icon provides a visual indication of the leak location.   The indicator includes a display configured to display a first representation of the part under test and a leak graphic positioned on the first representation, the position of the leak graphic being the leak location. The apparatus of claim 2 corresponding to a position of the first sensor proximate to.   The apparatus of claim 5, wherein the leak graphic is an animated graphic configured to simulate the tracer gas flowing out of the leak.   The apparatus of claim 1, wherein the leak detection signal is provided in response to a determination that a threshold amount of the tracer gas has been detected by at least one of the plurality of sensors.   The leak detection signal includes an indication of a first sensor, the first sensor being selected based on a determination that the at least one leak is positioned proximate to the first sensor. Item 8. The device according to Item 7.   9. The apparatus of claim 8, wherein the first sensor corresponds to the sensor that has detected the highest concentration of the tracer gas.   The apparatus of claim 8, wherein the first sensor corresponds to the sensor that first detected the presence of the tracer gas.   The apparatus of claim 1, wherein the leak detection signal includes an indication of a leak rate of the at least one leak.   The plurality of sensors are coupled to a fixture, and the fixture is configured to substantially surround the first region, and the leak rate of the at least one leak is increased over time by the plurality of sensors. The apparatus according to claim 11, wherein the apparatus is determined by obtaining a slope of an average concentration of the tracer gas detected in the step. A method of monitoring a part under test to determine if a first area contains a leak, comprising:
A step of disposing a plurality of sensors proximate to the first region, each of the plurality of sensors configured to detect the presence of tracer gas flowing out of the leak and to transmit a detection signal; Steps,
Monitoring each of the plurality of sensors to determine which of the plurality of sensors is detecting the tracer gas;
And at least a first sensor of the plurality of sensors transmitting a leak detection signal in response to detecting the presence of the tracer gas, wherein the leak detection signal is at least the first of the plurality of sensors. Including leak detection information representing the leak position in the first region based on the detection signals received from a sensor and a second sensor; and
A method comprising:   The method of claim 13, further comprising providing a first indication of the leak location.   The first display includes displaying on a display a first representation of a part under test and a sensor icon positioned on the first representation, the sensor icon being proximate to the leak location. 15. The method of claim 14, corresponding to the position of the first sensor.   The first display includes displaying on a display a first representation of a part under test and a leak graphic positioned on the first representation, the position of the leak graphic being the leak location. 15. The method of claim 14, corresponding to a position of the first sensor proximate to.   The step of disposing the plurality of sensors comprises coupling the plurality of sensors to at least a first fixture and positioning the first fixture adjacent to the first region. 14. The method of claim 13.   The first fixture is configured to substantially surround the first region such that tracer gas flowing out of the leak is substantially retained by the first fixture. 18. The method according to 17.   And further comprising providing a leak rate signal in response to at least a first sensor of the plurality of sensors detecting the presence of the tracer gas, the leak rate signal comprising the leak rate of the leak. The method of claim 18, comprising leak rate information representative of Providing the leak rate signal comprises:
Determining an average concentration of the plurality of sensors;
Monitoring a change in average density of the plurality of sensors over a first period; determining a rate of change of the average density over time;
The method of claim 18, comprising comparing the rate of change in average concentration with a known leak rate.   The leak detection signal includes information representative of the leak rate, and the method further includes a leak rate signal in response to at least a first sensor of the plurality of sensors detecting the presence of the tracer gas. The method of claim 13, comprising providing a second indication. A computer readable medium for use in leak testing applications to determine which of a plurality of sensors is proximate to a leak under a part under test,
Loading a data file corresponding to the position of the plurality of sensors, monitoring the plurality of sensors to determine which of the plurality of sensors detected the presence of a leak, and at least one of the plurality of sensors The leak position is determined when a first sensor detects the presence of the leak, and when at least the first sensor of the plurality of sensors detects the presence of the leak, the leak position is visually determined. Software part configured to provide an indication,
A computer-readable medium comprising:   The software portion further provides a first representation of the part under test and a first sensor representation of the at least first sensor positioned on at least the first representation of the part under test. 24. The computer readable medium of claim 22, configured to:   24. The computer readable medium of claim 23, wherein the visual representation of the at least first sensor is a sensor icon.   24. The computer readable medium of claim 23, wherein the first sensor representation is the visual indication of the leak location.   The software unit is further configured to determine the leak position by determining which of the plurality of sensors detects the maximum concentration of the tracer gas released from the part under test. The computer-readable medium of claim 22.   The software unit further determines the leak position by determining which of the plurality of sensors first detects the presence of the tracer gas released from the part under test. 23. The computer readable medium of claim 22, configured.   The computer readable medium of claim 22, wherein the software portion is further configured to determine a leak rate of the leak in the part under test. The software part is
Determining an average concentration of the tracer gas detected by the plurality of sensors, monitoring a change in the average concentration of the tracer gas detected by the plurality of sensors over a first period, and over a second period; Determining a rate of change of the average concentration of the tracer gas detected by the plurality of sensors, and comparing the rate of change of the average concentration of the tracer gas detected by the plurality of sensors with a known leak rate; 30. The computer readable medium of claim 28, configured to determine the leak rate of the leak in the part under test.   29. The computer readable computer program product of claim 28, wherein the software portion is further configured to provide a leak graphic positioned at a location proximate to the leak location on the first representation of the part under test. Medium. A sensor device for detecting the presence of leakage in a component under test pressurized with a gas including a tracer gas,
A housing;
A sensor configured to detect the presence of the tracer gas and generate a detection signal, at least a first portion of which is housed in the housing;
An I / O interface coupled to the housing and configured to provide a first connection corresponding to an analog output and a second connection corresponding to a network output;
A sensor controller connected to the sensor and the I / O interface and configured to generate an output signal based on the detection signal generated by the sensor, and further, the second of the I / O interface. A sensor controller configured to determine whether a network exists over the connection of the network, and to generate a data packet to be transmitted over the network when the network is present; ,
A sensor device comprising:   32. The sensor device of claim 31, wherein the sensor includes a heat transfer transducer.   35. The sensor device of claim 32, wherein a portion of the heat transfer transducer is accessible from outside the housing and is positioned proximate to the outside of the housing.   The outer first portion of the housing is configured to be coupled to a fixture, the fixture being configured to position the sensor device in proximity to the part under test. 34. The sensor device according to 33.   32. The sensor device of claim 31, wherein the sensor controller is configured to detect the presence of a first network and the presence of at least one additional network.   36. The sensor device of claim 35, wherein the sensor controller is configured to provide the analog output via the first connection when the first network and the at least one additional network are not present.   The sensor device is a stand-alone leak detection device, the sensor device further comprising a power source positioned within the housing and coupled to at least a sensor controller and an indicator visible from the outside of the housing. 34. The sensor device of claim 33, wherein the indicator is configured to provide an indication of the presence of the tracer gas. A gas sensor device for detecting the presence of gas,
A housing including a first outer surface;
A sensor configured to detect the presence of the gas and generate a sensing signal, including a transducer portion positioned proximate to the first outer surface of the housing to be accessible by the gas A sensor,
A sensor controller connected to the sensor and configured to generate an output signal based on the detection signal generated by the sensor;
With
The gas sensor device, wherein at least a part of the sensor and the sensor controller are accommodated in the housing.   39. The gas sensor apparatus of claim 38, further comprising an I / O interface coupled to the housing and configured to connect the sensor controller to at least one device remote from the gas sensor apparatus.   The output signal of the sensor controller is a normalized analog output signal representing the amount of gas detected by the sensor, and the normalized analog output signal is passed through a first connection of the I / O interface. 40. The gas sensor apparatus of claim 39, wherein the gas sensor apparatus is available on the at least one remote device.   The output signal of the sensor controller is a digital signal representative of the amount of the gas detected by the sensor, the digital signal via the second connection of the I / O interface. 40. The gas sensor apparatus according to claim 39, wherein the gas sensor apparatus can be used in a remote device.   42. The I / O interface further comprises at least one transceiver configured to receive the digital signal from the sensor controller and to generate and transmit a data packet including the digital signal. Gas sensor device.   The gas sensor device is connected to a CAN network, the I / O interface includes a CAN transceiver and a CAN controller, and the data packet generated by the CAN transceiver is transmitted to the at least one remote device via the CAN network. 43. The gas sensor apparatus of claim 42, readable by a device.   The gas sensor device is connected to the at least one remote device via an RS-485 connection, and the at least one transceiver is a data packet that is readable by the at least one remote device via the RS-485 connection. 43. The gas sensor device of claim 42, wherein the gas sensor device is configured to generate   39. An indicator configured to provide a visual indication signal, wherein the visual indication signal represents the presence of the gas, and the visual indication signal is viewable from the outside of the housing. Gas sensor device.   39. The gas sensor device of claim 38, wherein the sensor controller includes a threshold, and the output signal of the sensor controller includes an indication of whether the amount of the gas detected by the sensor exceeds the threshold.   40. The gas sensor apparatus of claim 38, wherein the sensor includes a heat transfer transducer.   The gas sensor device further comprises an I / O interface configured to connect the sensor controller to at least one device remote from the gas sensor device, wherein the housing of the gas sensor device is coupled to a component. The gas sensor device according to claim 38.   49. The gas sensor device of claim 48, wherein the component is a vehicle and the I / O interface connects the gas sensor device to a component controller of the vehicle.   50. The gas sensor device of claim 49, wherein the sensor of the gas sensor device includes a heat conduction transducer. A sensor device used in a network,
A housing;
A sensor configured to detect the presence of the tracer gas and generate a detection signal, the sensor including a first detection unit positioned to be accessible by the tracer gas;
A sensor controller connected to the sensor and configured to generate an output signal based on the detection signal generated by the sensor;
A network controller connected to the sensor controller and configured to generate a network data packet including information based on the output signal generated by the sensor controller;
A network interface connected to the network controller and configured to connect the sensor device to the network;
With
The housing is configured to house at least a first portion of the sensor, the sensor controller, and the network controller.   52. The sensor device of claim 51, wherein the sensor includes a heat transfer transducer.   53. The sensor device according to claim 52, wherein the sensor generates the detection signal based on an amount of the tracer gas detected by the heat conduction transducer. And an indicator coupled to the sensor controller, the indicator providing a first indicator configured to provide status information associated with the sensor device and an indication of the presence of the tracer gas. 52. The sensor device of claim 51, comprising a second indicator configured as described above.

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