EARLY DECISION TOOL
The brand new ATEQ Early Decision Tool is an innovative solution designed to optimize leak detection efficiency in manufacturing. This tool works by analyzing pressure conditions early in the test cycle, allowing for faster rejection of faulty parts and significantly reducing overall testing time.
By integrating real-time analysis, the Early Decision Tool can cut cycle times by up to 50% without compromising accuracy.
EARLY DECISION TOOL : PRINCIPLE
OPTIMIZE LEAK TESTING CYCLE TIME
The Early Decision Tool optimizes leak testing by quickly identifying defective parts before the full test cycle is completed. It works by analyzing pressure variations early in the process, allowing immediate rejection of faulty components. This proactive approach minimizes testing time, reduces waste, and enhances overall efficiency. By integrating this tool, manufacturers can streamline production while maintaining high-quality standards. Although it requires precise calibration, its ability to detect failures sooner makes it an essential addition for industries that demand fast and accurate leak detection.
Early Decision Tool Principle
Leak test a large volume requires a long stabilisation time before the test phase. The objective of the early-decision tool is to shorten this time, allowing to take a decision earlier and gain time. The long original cycle is divided into a succession of N short cycles.
For example (with N=5): Pr (original): FILL + STABILISATION + TEST + DUMP becomes:
- Pr1: FILL + STABILISATION + TEST
- Pr2: STABILISATION + TEST
- Pr3: STABILISATION + TEST
- Pr4: STABILISATION + TEST
- Pr5: STABILISATION + TEST + DUMP
BENEFITS OF USING THE EARLY DECISION TOOL
EARLY DECISION TOOL : OPERATION
LEARNING MODE
Thanks to a learning phase done on thousands of produced parts, the measurement curves are collected, and an uncertainty zone is defined.
PRODUCTION MODE
After defining the uncertainty zone, the production mode is initiated:
Pr1 is launched, followed by Pr2.
If the value measured in Pr2 is in the grey zone, no decision can be taken (undecided), Pr3 is launched.
If the value measured in Pr2 is in the green zone, the part is leak-free, A decision is taken: PASS and the test is stopped.
If the value measured in Pr2 is in the red zone, the part is leaking, A decision is taken: FAIL and the test is stopped.
The same procedure is followed until a decision (PASS or FAIL) is taken.
CONFORMITY PARAMATERS FOR THE PRODUCTION PHASE
Conformity parameters are added to limit the influence of unpredictable phenomena that can interfere with the measurement, such as a human intervention, an external air flow, a sudden change in temperature.
During the production mode if these parameters do not fall in between the imposed calculated limits for every one of the programs, a warning message is displayed.
EXAMPLE
Parameters
Pr (original): FILL (20s) + STAB (150s) + TEST (10s) +DUMP (20s) = 200s
We can divide into N = 5 with S(1) = 4s S(N) = 26.5s
- Pr1: FILL (20s) + STABILISATION (4s) + TEST (10s)
- Pr2: STABILISATION (26.5s) + TEST (10s)
- Pr3: STABILISATION (26.5s) + TEST (10s)
- Pr4: STABILISATION (26.5s) + TEST (10s)
- Pr5: STABILISATION (26.5s) + TEST (10s) + DUMP (20s)
Production phase: 1000 parts
If the early-decision tool is not activated, the total time
needed to test the 1000 parts is equal to 1000 times the duration
of Pr (original) (200s) = 200000 s
If the early-decision tool is activated = 99179.5 s
(Hypothetical distribution)
Optimized time = 50.4%
On average, the test passes from 200s to around 99.18s
| Decision taken at the end of cycle | Number of parts (%) | Total time needed per cycle (s) |
|---|---|---|
| Pr1 | 0 (0%) | 0 |
| Pr2 | 902 (90.2%) | 81631 |
| Pr3 | 53 (5.3%) | 6731 |
| Pr4 | 5 (0.5%) | 817.5 |
| Pr5 | 30 (3%) | 6000 |
| Early-decision default | 10 (1%) | 4000 |
| Total | 1000 (100%) | 99179.5 |
INDUSTRY APPLICATIONS USING THE EARLY DECISION TOOL
The Early Decision Tool is a smart, innovative way to make leak testing faster and more efficient. Instead of waiting for the entire test cycle to finish, it analyses pressure conditions early on, allowing faulty parts to be rejected much sooner. This means less wasted time, reduced scrap, and a more streamlined production process.
By integrating real-time analysis, the tool can cut cycle times by up to 50% while maintaining the same high level of accuracy. It quickly pinpoints defective parts before the full test cycle is complete, helping manufacturers boost productivity and uphold quality standards at the same time.
Curious to see it in action? Explore the tool here: ATEQ EDT Tool
The EDT can be applied across a wide range of industries and components that require leak or pressure-decay testing, including:
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Automotive – A/C systems, exhausts, fuel and brake lines, reservoirs
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E-mobility / Hydrogen / Battery systems – fuel cells, battery packs, hydrogen tanks
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Medical devices – catheters, fluid bags, vials, filters, syringes
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Packaging – bottles, caps, cosmetic and food packaging, plastic containers
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Consumer electronics – smartphones, smartwatches, cameras, drones
Essentially, any mass-production process involving pressure or leak integrity testing can potentially benefit from using the EDT.
The Early Decision Tool (EDT) is an intelligent leak testing solution that speeds up the decision-making process by analysing pressure trends early in the test cycle.
It works in two stages:
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Learning Mode – Thousands of measurement curves from real production parts are collected to define a reliable uncertainty zone. This creates clear green (pass), red (fail), and grey (undecided) areas.
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Production Mode – During testing, the tool checks the measured values against these zones. If the result falls in the green zone, the part is accepted early. If it falls in the red zone, it’s rejected immediately. Only grey-zone results continue through additional steps until a final decision is made.
By making accurate decisions earlier, the EDT helps manufacturers reduce cycle times while maintaining high precision and reliability.
Learning Mode
Production Mode
Curious to see it in action? Explore the tool here: ATEQ EDT Tool
