Automotive Plastic-Component Test Equipment
Dielectric withstand + airtightness in-line testing with auto load/unload, pass/fail sorting and per-unit data for MES
The dielectric integrity and sealing reliability of automotive electronic injection shells, connectors and sensor housings directly affect vehicle safety; manual offline sampling is prone to misses, misjudgment and untraceable data. ESML plastic-component test equipment integrates dielectric withstand and airtightness testing in one machine, automatically completing loading, hi-pot, leak testing and pass/fail sorting. It runs the identical test program on every piece (inline 100% inspection), archives per-unit test data and connects to MES/SCADA, supporting customers' IATF 16949 audit requirements for quality records, and has been delivered to an automotive electronics EMS production line.
Plastic-component in-line test · process blueprint
In-line test process for plastic components
Auto loading & locating
- Parts are automatically fed and located; test electrodes and sealing/fill couplings engage automatically
Dielectric withstand
- Applies the specified test voltage and automatically judges leakage current and breakdown
Airtightness / leak test
- Seals and pressurizes the cavity, then judges via pressure-decay/direct-pressure/flow against the allowed leak rate
Visual & dimensional check
- Vision checks appearance and key dimensions; an optional station configured per product need
Sorting & data logging
- Pass/reject parts are diverted to separate lanes to prevent mixing; per-unit results are archived
Core test capabilities
Multi-parameter integration
Dielectric withstand + airtightness in one cell, extensible to visual/dimensional checks, reducing station changes
Inline 100% inspection
Every piece runs the same test program, replacing offline sampling and avoiding human misses
Auto sorting, no mixing
Pass and reject parts divert to separate lanes, preventing escape and mixed parts
Per-unit traceability
Per-unit test data is archived for batch/piece traceability and MES/SCADA integration
Applicable workpieces
Auto electronic injection shell
Inline hi-pot + airtightness test and sorting, delivered to an automotive electronics EMS
View case →Connector housing
Dielectric and seal testing; electrodes and sealing tooling customized per pin layout
Sensor plastic housing
Airtightness and dielectric test adaptable, with leak stations configured per sensor type
Plastic cap / valve housing
Structural parts requiring leak or hi-pot judgment, extendable on the same platform
Selection parameters
Reference parameters; test voltage, leak thresholds and cycle time are confirmed per product standard, allowed leak rate and capacity, with concrete values provided at the proposal stage.
| Metric | Value | Notes |
|---|---|---|
| Test items | Dielectric withstand + airtightness | Visual / dimensional station optional |
| Inspection mode | Inline 100% inspection | Replaces manual offline sampling |
| Leak-test method | Pressure decay / direct / flow | Chosen by allowed leak rate and takt |
| Hi-pot criteria | Voltage / leakage / hold time | Set per product standard & customer spec |
| Load/unload & sorting | Auto load/unload + pass/fail sorting | Prevents mixing and escape |
| Traceability | Per-unit test data archived | Batch / per-piece traceability |
| Data & quality system | MES / SCADA · IATF 16949 | Standard protocols; meets record needs |
| Delivery / response | ~60-day standard · 24h response | Confirmed per test items & capacity |
Reference case
Plastic-component testing FAQ
What tests do automotive plastic parts need?
Which leak-test method is used and how is the leak limit set?
What are the hi-pot test voltage and pass criteria?
How does inline automated testing beat manual offline sampling?
Can it connect to MES with per-piece traceability? What about takt and lead time?
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