Leak Testing Case Studies: Automotive Brake Leak and Flow Testing

Client: Leading Automotive Brake Parts Supplier

Part: Brake Assembly

Machine supplied: Leak and Flow Testing Bench with Twin Stations

Overview: This system was designed and manufactured in order to give the customer the ability to leak and flow test brake assemblies within their production environment. TQC developed this system alongside the client to allow them to supply qaulity, tested parts to their customers.
Download details of this system as a PDF


TQC have recently developed an innovative system for the automatic testing of high specification brake parts.

The operator manually loads a part into the machine and connects the test line to it. Firstly, an air flow test is performed to check for blockage. If successful, the part is automatically shrouded in a close fitting test chamber and 3 successive leak tests are performed using a differential leak test instrument as follows -

1. Intermediate pressure leak test (including piston movement check)
2. Low pressure leak test - 0.5bar
3. High pressure leak test - upto 160 bar

Good parts are pass stamped on completion.
Two stations allow the leak tests to be carried out on one station while the flow test is carried out on the other and vice versa.

To allow testing of different sizes and types of arts, interchangeable tooling is supplied.

  • Standard aluminium extrusion bench
  • Universal fixture areas
  • Light guard access to each station
  • Fully automatic sealing fixture
  • PLC control system
  • Built in differential leak test instrument
  • Standard operator interface panel
  • Suitable for medium to high volume applications

Leak Test Description

All the leak tests check for zero brake fluid leakage at various service pressure conditions.

  • 1st leak test is performed at 2 bar
  • 2nd leak test is performed at 0.5 bar
  • 3rd leak test is selectable between 35 bar and 160 bar.
  • Nominal throughput is approximately 1 part per minute on a 2-station machine.

This bespoke test system is based around the standard TQC series 40 range of equipment.


To find out more about how we can help you with your leak testing requirements:

We build all machines in-house, applying our 25+ years experience in specialised test and automated handling machines experience to the engineering projects we undertake. We offer customer support, backup and service call-out for all projects, whatever the size.

Get in touch with us to discuss your requirements and we will be happy to offer our professional advice and visit you at your site.

TQC Ltd, Hooton Street, Carlton Road, Nottingham, NG3 2NJ, United Kingdom
Tel: +44 (0)115 9503561   |   Fax: +44 (0)115 9484642   |   E-mail: sales@tqc.co.ukSGS