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Introduction Oxygen systems in aircraft and aerospace applications demand the highest integrity: even minute leaks can pose serious safety risks—fire hazards in enriched-oxygen environments, system failures at altitude, and non-compliance with military and NASA standards. The KU- 7 Oxygen Tester uses high-purity nitrogen as an inert test medium to eliminate combustion risk during pressurization. Its dual-range capability (up to 4000 psi and down to 50 psi) covers both qualification (high-pressure endurance) and acceptance (fine-leak characterization) regimes, per guidelines in NASA-STD-7012 for leak-test sensitivity (down to ~1×10−4 mbar·L/s). Mounted on a compact trolley, the tester travels easily from hangar bay to flight-line, enabling on-site verification without dismantling large assemblies. Key Features - Dual-Stage Pressure Control: Two independent regulators tame shop-air (6,000 psi) down to test pressures of 4,000 psi (qualification) and 50 psi (acceptance), supporting rapid switch-over between test modes. - High Sensitivity Leak Detection: Chamber and gauge calibration ensure detection of leaks as small as 1×10−4 mbar·L/s, compliant with aerospace leak-test requirements. - Robust Chamber Design: Precision-machined mild-steel chamber with O-ring seals and quick-release clamps maintains uniform gasket compression, delivering consistent dwell-time pressure hold tests. - Integrated Flow Monitoring: A rotameter (0–6 SCFH) allows trace-gas methods (e.g., helium sniff) and confirms purge rates for rapid localization of leaks. - Safety Protections: Dual pressure-relief valves (0–10 bar) and color-coded warning labels mitigate overpressure incidents, while needle-valve arrangements isolate test circuits before venting. - Data Logging (Optional): Add-on digital transducers and USB/ethernet output enable automated test reports and trend-analysis for recurring maintenance. - Portability & Ergonomics: Lockable swivel casters, integrated handle, and a footprint under 2 ft2 let technicians maneuver in tight spaces without cranes or dollies. Applications • Aircraft Oxygen Supply Maintenance: Verification of regulators, manifold assemblies, and pressure-demand valves during scheduled A-checks and C-checks, ensuring leak-tight integrity before flight. • Defense Subsystems QA/QC: Factory acceptance testing of breathing-air packs and escape-system bottles to MIL-PRF-25567 standards for oxygen leak-detection compounds. • Spaceflight Hardware Validation: Pre-launch inspection of portable life-support units and EVA backpacks, tailored to meet NASA and DoD leak-test protocols. • Laboratory & R&D Prototyping: Rapid research-bench checks on novel valve designs, materials compatibility studies under oxygen service, and developmental test cycles for new gas-handling components. System Description 1. Leak Chamber: 10 × 20 in. cylindrical vessel, chrome-plated interior, with six port fittings for various UUT geometries. 2. Pressure Regulators & Gauges: Precision back-pressure regulators with ±0.5% full-scale accuracy; gauges cover 0–8600 psi, 0–140 psi, and 0–60 psi ranges. 3. Needle Valves & Isolation: Five metering valves (1⁄4′′ OD tubing, 345 bar rating) route gas to test ports, purge lines, and relief vents; quick-disconnect fittings permit rapid reconfiguration. 4. Flowmeter (Rotameter): Glass tube with a stainless-steel float, readable to ±2% accuracy for flow-rate verification before sealed-chamber tests. 5. Safety Valves: Two spring-loaded relief valves calibrated at 10 bar; built-in burst discs for catastrophic-event protection. 6. Chassis & Mobility: Welded tubular-steel frame, powder-coated for corrosion resistance, with four 5′′ polyurethane wheels (two locking) and ergonomic tug handle. Technical Specifications
