73 calibration to ensure accuracy and reliability. Some companies offer ISO 17025-accredited services for certified calibration and support. Some systems include seals or fixtures that can be serviced as part of routine preventative maintenance schedules, reducing unexpected downtime. Maintenance needs differ, based on the type of data required. Systems providing qualitative leak detection typically need regular servicing of electromechanical components, such as pumps and gas generators, but they do not require calibration. Quantitative systems, however, require calibration of parts such as mass flow sensors to maintain measurement precision. Some advanced leak detectors feature extended maintenance intervals, with sensors warrantied for several years. Maintenance is often limited to replacing dust filters, small mechanical parts or oil reservoirs in vacuum pumps. Many detectors remain in operation for decades, with upgrades driven more by technological advancements than equipment failure. Certain manufacturers integrate selfcalibration or optimised components to minimise maintenance needs. Some systems automatically calibrate to the testing environment before each use, reducing the burden on operators. Factory calibrations are verified as per OEM specifications, eliminating frequent adjustments. Overall, maintenance requirements depend on the specific detection technology, system design and intended application, with some units requiring minimal servicing beyond basic component replacement. Lifespan varies by design and maintenance requirements, but many leak detection systems are engineered for long-term durability with minimal upkeep, making them a long-term investment. Some equipment is built to last over 20 years, requiring only minor component replacements, such as valve seals and filters. Other systems are designed for at least 10 years with proper maintenance. Systems using colour-change detection media or challenge gases need these materials replenished regularly, but that does not affect the system’s overall lifespan. Some advanced systems incorporate zeromaintenance components, reducing the need for servicing. Modular or software-updatable architectures increasingly feature, allowing systems to adapt to new vehicle models, battery configurations or testing standards without requiring hardware replacements. Costs and scalability vary, depending on the system design, specific product features and scale of manufacturing. Some simpler leak detection systems, typically for production testing, range from $10,000 to $35,000, with some models reaching up to $50,000, although these prices cover the detection technology only, not complete systems, according to a leading supplier of mass spectrometry and vacuum decay equipment. More complex setups, such as those integrated into production lines, can cost $100,000 to $200,000, depending on the level of automation, the number of test chambers and throughput capacity. However, additional features such as multi-chamber systems and high-speed pumps can scale the cost, based on performance needs. Many leak detectors are modular, allowing for easy adaptation as production requirements grow. For instance, detectors with a single test chamber can be scaled up by adding more chambers or larger pumps to meet the demands of high-volume production lines. Systems can also be customised for specific sensitivities, meaning users can choose a detector with just enough sensitivity for their needs. This allows for faster test speeds while avoiding overpaying for excessive sensitivity. Future directions As leak detection requirements and technologies evolve, a number of trends are observable. One is a focus on smaller leaks and more sensitive, automated testing. Another is increased use on production lines of 100% rather than sample testing, along with data-driven early warnings to spot production issues before failure thresholds are crossed. Also, there is potential benefit in exploration of visual technologies from cameras to X-rays in the longer term, although resolution and AI interpretation need to improve before they are viable for the detection of the smallest leaks. For the moment, traditional methods proving substance escape remain most reliable. Acknowledgements The author would like to thank the following for their help with this article: Jean Luc Regef, CEO, and Jeremie Hernandez, Technical Training Manager of ATEQ Group; Jens Buhlinger, Battery Technology Development, Eaton Mobility Group; Jeff Ellis, senior technology leader at EWI; Sandra Seitz, automotive market manager, leak detection, at INFICON, and Alex Parker, president of Redline Detection. E-Mobility Engineering | March/April 2025 The HX-490S Dual Gas is a helium/hydrogen tracer gas leak detector designed specifically for industrial environments, which features a fast responding industrial-grade mass spectrometer in a small footprint (Image courtesy of ATEQ)
RkJQdWJsaXNoZXIy MjI2Mzk4