In our previous article, we introduced why helium leak testing has become essential for ensuring the long-term reliability of high-voltage relays. But understanding its importance is only the first step.
The real challenge for many manufacturers is this:
How do you select the right Helium Leak Testing Equipment when every production line, relay structure, and testing standard is different?
The truth is—there is no “one-size-fits-all" solution. But the process becomes clear when you evaluate the following factors step by step.
1. Determine the Target Leak Rate (Sensitivity Requirement)
High-voltage relays typically require detection sensitivities ranging from 10⁻⁵ to 10⁻⁹ mbar·L/s.
Use this guideline:
- General sealed relays → 10⁻⁵ to 10⁻⁶
- High-reliability relays (EV, aerospace, grid-level protection) → 10⁻⁷
- Critical HV protection relays → 10⁻⁸ to 10⁻⁹
Choosing a tester with inadequate sensitivity is the #1 reason for product failures in the field.
2. Choose the Right Testing Method
There are two major helium testing approaches:
A. Vacuum Chamber Method (Mass Spectrometer)
Best for:
- High-precision requirements
- Safety-critical HV relays
- Small-to-medium production volumes
Advantages:
- Ultra-high sensitivity
- Reliable, repeatable results
- Detects micro-cracks invisible to air testing
B. Helium Sniffer Method
Best for:
- Large parts
- Flexible production
- Fast troubleshooting in workshops
Advantages:
- Lower cost
- Easy to operate
- Great for leak location pinpointing
If your relay must be 100% sealed, vacuum testing is the industry-standard choice.
3. Consider Your Production Scale
Different production volumes require different levels of automation:
- Small batches → Manual or semi-automatic testing
- Mid-size factories → Multi-station systems
- High-volume OEM production → Fully automated helium filling, pressurizing, testing & evacuation line
Automation matters because it affects:
- Cycle time
- Test repeatability
- Labor cost
- Data traceability
For example:
A relay factory producing 5,000–20,000 pcs/day will often use continuous automatic helium test lines to maintain output consistency.
4. Verify Compatibility with International Standards
Depending on your market, ensure compliance with:
- IEC
- UL
- ISO
- GB/T
- Automotive OEM standards
Helium leak testing requirements differ among industries, especially for EV relays and high-voltage protection devices.
5. Evaluate Cost vs. Long-Term ROI
A common misconception is that helium testing is “expensive."
In reality, it saves manufacturers money by reducing:
- Warranty returns
- Field failures
- Manual re-testing
- Production inconsistencies
The ROI often becomes visible within 6 to 12 months, especially for high-voltage relay manufacturers.
7. Partner With a Manufacturer That Understands HV Relays
Choosing a helium tester is not only about equipment—it’s about expertise.
A good supplier will provide:
- Relay-specific fixture design
- Process consulting
- Helium charging/evacuation optimization
- Maintenance training
- Calibration & after-sales support
This is often the deciding factor between a system that “works" and a system that delivers consistent factory-level reliability.
Conclusion
Selecting the right Helium Leak Testing Equipment for high-voltage relays doesn’t have to be overwhelming.
By understanding your required sensitivity, testing method, production volume, standards, and long-term ROI, you can make a choice that guarantees:
- Better product quality
- Higher reliability
- Stronger market competitiveness
- And—most importantly—zero-compromise safety for your end-users.
Open Question for the NEXT Blog
High-voltage relay manufacturers often ask us:
“How can we reduce helium consumption and testing costs while keeping high sensitivity?"
This is the challenge many factories face today, especially with rising helium prices.
In our next blog, we will reveal smart strategies to reduce helium usage by up to 60%, without sacrificing detection performance.
Stay tuned.
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