We worked with Gems Sensors & Controls to improve a sealed part leak tester used for ultrasonically welded plastic floats. The goal of the project was to help move the company’s current leak testing process from batch testing to a one-piece-flow system, where each float could be tested individually using controlled air pressure. Our team focused on both mechanical and electrical improvements to make the tester safer, easier to use, and more suitable for production. This included modifying the physical tester, improving the machine enclosure, updating the HMI interface, adding clearer pass/fail indication, and working on PLC wiring and control logic. We also calculated the required air transfer chamber volume, helped design the transfer chamber, and developed leak test parameters for the ATEQ F620 leak decay tester. The project also involved testing and validation to make sure the system could properly detect good and defective floats. In addition, we created visual work instructions to help operators understand and use the machine correctly. Overall, this project gave us hands-on experience with electromechanical design, automation, controls, testing, and real-world manufacturing process improvement.

Our team collaborated with Mechanical Engineering 23 on this project.