Applications of JCGK Leak Detection Equipment from Jingcheng Engineering in the Automotive Industry: From Component Testing to Supply Chain Collaboration

On a new energy vehicle production line, a battery pack, a thermal management system, a valve assembly, or even a connector,Any product with internal gas or liquid passages or sealed chambers must pass a gas tightness test before leaving the factory.The

In the past, this type of testing was mainly done in laboratories, where a few samples were taken and analyzed.Now it goes straight into the smart manufacturing production line, where every product is inspected.The
This is because the sealing requirements for new energy vehicles are much higher than those for gasoline-powered vehicles. Even a small leak of water or air can trigger a chain reaction of problems.

Shenzhen Jingchenggongke Technology Co., Ltd.(JCGK) has long been deeply involved in the automotive parts and new energy sectors, establishing a comprehensive portfolio ranging fromAirtightness testing equipment, from inspection fixtures to automation integration and data traceabilityits comprehensive solution capabilities. According to publicly available information, Jingcheng Engineering has served more than 3,600 well-known clients worldwide, spanning industries such as new energy, automotive parts, consumer electronics, medical devices, robotics, aerospace and defense, and liquid cooling.

Q1: Why is airtightness testing becoming increasingly important in the automotive industry?

As automobiles are evolving from mechanical products into highly integrated mechatronic systems, the consequences of seal failure are becoming increasingly complex.

The Era of Traditional Gas-Powered Vehicles, Leak testing primarily focuses onEngine, transmission, fuel system, braking system, air conditioning system, and certain valve bodies and lines. The inspection requirements for these components are relatively fixed, and the overall scope is limited.

Since the advent of new energy vehicles, the scope of the inspection has been expanded toPower battery packs, battery enclosures, battery cooling systems, liquid-cooled plates, drive motors, electronic control systems, thermal management systems, various valve assemblies, automotive sensors, connectors, and pipe fittings, etc.. Jingcheng Engineering’s automotive industry solutions also list a variety of airtightness testing application cases, including automotive sensors, diaphragm pumps, water-cooled plates, brakes, and instrument panels.

In the automotive industry, air-tightness testing is expanding from a few key assemblies to cover an increasing number of components as part of quality control processes.

Q2: Why is airtightness testing particularly important for new energy vehicles?

Because new energy vehicles incorporate a large number of systems that are highly sensitive to sealing performance, a failure in any one of them could trigger a chain reaction.

Power batteries not only need to prevent the ingress of external moisture and dust, but their internal structure also imposes strict requirements on sealing reliability.In a liquid-cooling system, any leak in the liquid-cooling plate, cooling lines, or fittings can result in the loss of coolant, which directly affects the normal operation of the thermal management system and, in severe cases, may even pose a safety hazard.The

For mass-production companies, airtightness testing is no longer “Let's take a few samples and take a look." quality spot checks. The real challenge lies in:How can inspection be reliably integrated into the production line to ensure it is fast, repeatable, and traceable?
This is precisely the key driver behind the transition of automotive parts airtightness testing equipment from laboratory instruments to in-line testing systems.

Q3: What methods are generally used to test the airtightness of automotive parts?

There is no single method that works for all automotive parts. The actual selection depends on a comprehensive balance of factors such as product volume, allowable leakage rate, test pressure, production cycle time, and inspection accuracy.

direct pressureThe most direct way is,Gas is introduced into the test piece at a specified pressure, and leaks are detected by measuring the rate of pressure drop.. This method has a clear principle, offers fast testing speeds, and involves relatively simple system setup, making it suitable for batch inspection of large quantities of standard industrial components.

differential pressureIt is better suited for applications that require sensitivity to minute pressure changes and high repeatability.Pressure is applied simultaneously to the reference chamber and the workpiece under test, and a high-precision differential pressure sensor is used to compare the pressure changes on both sides to detect leaks.Precision Engineering's JC-C10005 The series differential pressure measurement, combined with temperature compensation, effectively reduces the impact of environmental factors on test results.

flow rate methodpass (a bill or inspection etc)Monitor the flow rate of the gas required to maintain the test pressure to estimate product leakage., and offers good engineering compatibility with certain automotive components.

High-Sensitivity Detection Methods, Such as Helium Mass SpectrometryThis is reserved for products with specific requirements regarding maximum leakage rates.

However, in actual mass production environments, not all automotive components require inspection methods with the highest sensitivity.Test accuracy that is sufficient for the application, cycle time matching, reasonable costs, and the ability to achieve stable mass production are often more important than simply pursuing higher sensitivity.

Q4: Why is there an increasing emphasis on automation in leak testing for automotive parts?

This is because what the automotive industry really cares about isn’t “whether it can be tested,” but “whether every product can be tested consistently.”

A single production line produces thousands—or even more—parts every day. If we continue to rely on manual labor to complete the entire process—including clamping, applying pressure, waiting, taking readings, making judgments, and recording data—efficiency is a problem, but data integrity and consistency of results are even bigger issues—Errors in manual readings, missed inspections, incorrect inspections, and inability to trace batches...Any of these issues could create potential problems in subsequent quality control.

As a result, leak testing for modern automotive parts is increasingly moving towardAutomatic loading + automatic clamping + automatic inflation + automatic inspection + automatic evaluation + automatic recordingA complete closed-loop system.Jingcheng Engineering currently offers direct-pressure, differential-pressure, flow-based, fixed-volume, and positive/negative pressure hybrid types, among others.Air tightness testing equipment, and supports multi-channel and custom solutionsThe

Q5: Why do auto parts manufacturers still need custom tooling?

Because the sealing interfaces, connections, and cavity structures of different components vary significantly, generic tooling cannot address customized sealing challenges.

Sensors require seals designed for their interface locations; water-cooling plates require precise sealing of their inlet and outlet ports; valve bodies must be compatible with different gas ports; battery enclosures require fixtures designed around the overall sealing perimeter; and connectors must address sealing issues at ports and wiring harness interfaces.

This means that a true airtightness testing solution is usually not “Just buy one instrument and you're done", but ratherleak detector + Tooling and Fixtures + Pneumatic Systems + PLC + Automation Mechanisms + Data Systemstogether form a complete testing unit. This is also why Jingcheng Engineering has expanded its focus from simply supplying equipment to “Fully automated airtightness testing program"The root cause of ."

Q6: Why is the automotive industry placing increasing importance on test data?

This is because the automotive supply chain of the future will require not only that “products meet specifications,” but also that “it can be demonstrated why the products meet those specifications.”

After an automotive component undergoes a leak test, a complete data record is generated that includes the product number, test pressure, hold time, leakage rate, pass/fail result, test time, and production batch. By connecting to systems such as PLCs and MES via a communication interface, it is possible to establishProduct—Test Data—Production BatchThe traceback relationship between them.

New Energy Vehicle Domain ControllerAirtightness Tester

If quality issues arise later on, the company can trace the source:Who manufactured these products, when were they manufactured, and what are the actual leakage levels? Given the automotive industry’s increasingly stringent quality management systems, this information is far more valuable than a single inspection.

Q7: How was Jingcheng Engineering (JCGK) able to break into the automotive supply chain?

The key is not the performance specifications of a single instrument, but rather an understanding of the actual production requirements for automotive parts.

The automotive industry's response toAir tightness testing equipmentThe requirements are multifaceted.

• accurateIn this regard, the equipment must meet the leakage rate criteria specified for the product;
• stabilityIn this regard, consecutive test results for the same product must demonstrate good repeatability;
• BeatIn this regard, the equipment must keep up with the production speed of the mass production line;
• WorkwearIn this regard, it is necessary to quickly adapt testing fixtures to different product configurations;
• AutomationIn this regard, it must operate in coordination with the loading and unloading mechanisms, the PLC, and the entire production line;
• DataIn this regard, support is needed for storing test results and ensuring quality traceability.

Taken together, these requirements mean:What the automotive industry really needs isn't just oneairtightness meter...but rather a testing system that can be implemented on the production floor, and Jingcheng Engineering—with its many years of specialized experience in leak testing for the automotive industry—is perfectly positioned to meet these needs.

Q8: What experience has Jingcheng Engineering accumulated in the automotive industry?

Based on publicly available information, Jingcheng Engineering has established a relatively comprehensive system of automotive parts application case studies.

Its automotive industry applications page currently showcases applications such as leak testing for automotive sensors, leak testing for automotive diaphragm pumps, leak testing for automotive components, leak testing for in-vehicle center displays, leak testing for automotive brakes, leak testing for instrument panels, and leak testing for water-cooled plates.

The partner brands publicly listed on Jingcheng Engineering’s official website include Huawei, Gree, Xiaomi, BYD, Foxconn, EVE Energy, Sunwoda, Luxshare Precision, Honeycomb Energy, and Kodali, among others. Furthermore, some Fortune 500 companies have designated Jingcheng Engineering as their preferred supplier.

Q9: How to Choose Auto PartsAir Tightness Leak Detection Equipment?

Instead of asking, “Which instrument is the most accurate?” you should first identify the five key parameters.

Selection Parameters	Issues Decided
test pressure	Instrument Pressure Range and Pneumatic Circuit Design
Permissible Leakage Rate	Selection of Methods Such as Direct Pressure, Differential Pressure, and Flow Measurement
Workpiece Volume	Setting the Inflation, Stabilization, and Test Times
Production Line Cycle Time	Single-channel or multi-channel solution
Automation Requirements	PLC, I/O, Communication, and Tooling Solutions

For small automotive components such as sensors, valve bodies, and connectors, the focus is onAccuracy, Repeatability, and Test Cycle Time. For larger structural components, such as water-cooling plates and battery enclosures, further consideration is neededVolume, pressure range, fixture sealing, and test duration. For mass production line projects, production tooling, automation, communications, and data traceability must be factored into the overall selection process; one cannot focus solely on the instrument specifications themselves.

Conclusion

The automotive industry is undergoing a profound transformation—shifting from internal combustion engine vehicles to new energy vehicles, and from mechanical manufacturing to smart manufacturing. Competition within the supply chain has also shifted from “Who can manufacture it?"Turn" "Who can produce faster, more reliably, and at a lower cost—and back up the quality with data?"The

Jingcheng Engineering (JCGK) addresses this need byAirtightness Tester,Air Tightness Leak Detection Equipment,Sealing Tester,Waterproof Test Equipment, workholding fixtures, and automation solutions, providing manufacturing companies with solutions ranging from single-machine inspection to production line integration. According to publicly available information, the company’s business has expanded to regions including Asia-Pacific, Europe, and North America; it holds export qualifications and is capable of supporting global supply chains.
For automotive parts companies, “Domestic or Imported"That label isn't important."The key is whether this inspection solution can meet the leak rate requirements, keep up with the production line’s cycle time, operate reliably, perform automatic judgment, and record complete quality data.The

Companies with specific needs for waterproofing, sealing, or leak detection can contact JCGK directly for a free consultation on available solutions.

Original Statement:this paper was written byShenzhen Jingchenggongke Technology Co., Ltd.Written by the technical team, reproduced with attribution.Data sources: Precision Engineering internal test data and customer cases.