Dry Calibration and Test of Gasoline Injectors

The automatic production line calibrates and tests PFI injectors.
A robot loads the injectors from pallets and puts them onto pucks at a conveyor system.
This conveyor connects all substations at the line.
The first substation at the conveyor is a code reading station where the part is identified.
After that, the parts are moved to the rotary table where the test substations are located.
Before the part arrives at the final dressing stations at the conveyor it can be transferred to the hydraulic audit cell. Within the audit cell the part is supplied with test fuel and tested in static and dynamic mode again.
These results are used as reference values to align the dry process to the wet conditions.
Before the robot finally offloads the injector the lower O-ring is mounted and the electrical pins of the terminal are checked by a camera.


GDI High Pressure Pump Performance Test Bench

The system is used to test cam driven high-pressure fuel pumps. The test bench simulates the mechanical drive and the low and high-pressure circuit.
The high-pressure pump is mounted manually on the CAM box and contacted by hand.
A change to other types of pumps is realized by changing the CAM-Box and the connection devices. The serial number of the pump can be read by a hand scanner.
There is also the possibility at the high-pressure output side of the pump to connect a customer specific rail, which is equipped with up to four injectors. These injectors can be controlled through the software or with a custom AUTO ECU. Measured signals are torque, current / voltage of the control valve, pressure and flow rates of the pump and injectors.
The inspection specifications are carried out by a database-flexible test plan system.
Individual test steps can be configured in any order and number and with different parameter settings to a flowchart. The results are recorded in a central database.


GDI Injector Flow and MOP

This test bench is used for the function testing of GDI-Injectors. Different injector types can be tested be means of adapters.
The bench is divided into two independent stations. In the flow station the injection quantity is tested by a Coriolis sensor and the injection timing is tested by a shotto-
shot system.
The spray station evaluates the injector spray. Not only ray, but also bottom view measurements are possible. The station allows manual tests and fully automatic test
sequences. All test parameters, like operating pressure, pulse width, injection frequency, can be set over the software.


GDI Injector Flow and Leak Test

This test rig provides the possibility to test the flow and leak values of a GDI-Injector. The rig has one central high-pressure supply and two separate stations.
The rig is realized with ATEX components and can be used with potentially explosive fluids.
A fast data acquisition allows to measure the current and voltage course on the injector.
An acceleration sensor can detect the opening and closing time of the injector.
The seat leakage measurement is done in wet condition.


Flow Test Bench Valve Seat

The flow test bench is used for verification of valve seats in GDI injectors.
The workpieces are manually loaded into the test station. The test bench offers high flexibility due to a simple change of the valve seat fixtures and a single changeover dialogue in the software.
The fully automated control software allows easy handling and high flexibility. Results and current values are displayed in the main window to guarantee an easy overview of the process.


“Dry Calibration“ of Gasoline Injectors

R&D bench for calibration and test of low pressure gasoline injectors in dry condition.
The obtained data and results are used for high-volume production process development.
In order to obtain detailed data sets, several measurement systems are combined with rapid data acquisition.
The recorded parameters and results are evaluated using the data analysis tool MATLAB.
The separation of data recording and analysis allows post processing of data with different settings and algorithms at any time.


Leakage Test for Gasoline Injectors

Test machine including five stations for measurement of valve seat leakage.
Automatic loading with conveyor interface to production line. High leakage injectors are classified and offloaded separately.


EOL Liquid Leak Test for GDI injectors

This test bench is an automatic system for the leak test of gasoline injectors.
The part handling takes the injectors from a conveyor belt and puts them in the nests of a rotary table. DMC-code of injector as well as RFID-code of the conveyor pallet are automatically transferred to a database. Now, the rotary table takes the parts to the run-in station and next to the
distribution axis.
The axis transports the test parts to the leak test stations. After the test, the injectors come back to the rotary table and the blow-out station. Finally, the parts get back to the pallet conveyor.


GDI injector flow and spray test bench

The test bench is designed for the entire analysis of important parameters of GDI-fuel injectors. Explosion protected components enable the operation with n-heptane as test fluid.
The bench provides the following test functions:

• Dynamic test in mg/inj (volumetric/gravimetric / shot-to-shot analysis)
• Static flow test in g/min (volumetric/gravimetric)
• Measurement of opening and closing times
• Injector spray characteristic (axial / radial spray geometry).


Spray and Flow Test Bench

The test bench is designed for the investigation of geometrical spray characteristics and for the static flow measurement of tow different Injector Sede types.
After the manual loading of the test parts, the complete automatic test sequence starts including the analysis of spray characteristics and flow data. The spray test cavity is configured for axial light sheet inspections. A motorized traversing system positions the axial light sheet optics.


Assembly and Final Test for GDI Injector Coils

This machine is used for preassembly and testing of coils for GDI injectors.
After the check by the operator the workpieces are inserted into workpiece carriers.
A conveyor belt is used to transport the parts to the preassembly stations where the o-rings and bodies are feeded by bowl feeders. The body and coil are fitted together with a press-in station.
The testing equipment has a rotary dial with an on- and offload station as well as additional testing stations. These are used for verifying different coil features. A laser marking station marks the coils with a Data Matrix Code.
It is possible to run mechanically two different coil types. A change-over is done automatically after selection by software. In addition, the workpiece carriers on the rotary table have to
be changed.


Final Check for Injector Coil

This machine is used for the final testing of coils for gasoline injectors.
After the check by the operator, the workpieces will be inserted into the workpiece carriers.
The test equipment has a rotary dial with an on- and offload station as well as additional testing stations.
These are used for verifying different coil features. A laser marking station marks the coils with a Data Matrix Code. It is possible to run mechanically two different coil types.
A change-over is done automatically after a selection by software. In addition, the workpiece carriers on the rotary table have to be changed.


Preassembly Injector Coil

This machine is used for preassembly and testing of coils for an gasoline injector.
The feeding of the body is performed by a bowl feeder. An numeric controlled axis takes the body from the unloading position and inserts the workpiece into the rotary dial.
A rotation station moves the body in a defined position. The next station is used for feeding the coil itself and inserts it into the body.
The next station is used to press-in the cover on the body. During the press-in process a force-stroke-diagram is recorded and evaluated.
An additional station is present to measure the resistance and inductance of the coil. A marker is marking OK parts. Finally, the parts are offloaded from the rotary dial into pallets
by means of an electrical axis. A pallet change over is done automatically.




此检测台用于极限温度条件下的Piezo压电喷射器的流量检测,如同它在内燃机中出现的。Exxsol或者n-Heptan可作为检测液被使用。可能的温度范围在-40°C +150°C 之间,在此工作腔温度与介质温度的温度差最多可达到150°C。工作腔内包含4个喷射器工作台。每个工作台可以最多放置6Piezo压电喷射器。流量能通过一个Coriolis-流量测试仪或者水平仪选择性测量。






  • 为了达到较短的节拍时间,对过滤件预先挤压
  • 通过特别的输出端启动线圈检测
  • 静态流量的测量
  • 动态流量的校准
  • 调节后的动态流量重复测量
  • 通过专利的测量方法确定喷射器底座的泄漏
  • 标识夹的组装




  • 定位精度的明显增加
  • 通过微脉冲-推动,在按压时把粘滑作用降低到最小
  • 通过静态的最小力负荷,降低零件受到的应力
  • 针对电荷影响和过盈配合公差变量具有强力的智能化进程控制
  • 降低了定位时零件弹性变形的影响




  • 在无压的区域里,使用高精度电子秤的重量测量系统
  • 在施压的区域里,使用Siemens的Coriolis测量仪的体积测量系统


  • 在压降的喷射检测腔内,存在的相对压力范围为-0,7…10 bar(氮气)
  • 激光振动计安置在轴向下方的工作腔法兰上,用于无接触的压电喷射器的开启冲程检测
  • 体积性的照相测量仪 PLU 131 HD STS,测量单次喷射量和喷射过程
  • 在温度范围-32…140°C内,可对喷射器夹具和检测燃料分开调整


  • 检测压力范围在20…320 bar的Sonplas压力增压器
  • 来自气体-光度计(NDIR)  Fresenius公司,用于浓度检测的燃料-氮气混合物,它从四周冲刷喷射器


此检测台用来试验GDI-喷射器的所有重要特性。它装配了防爆组件。检测液可为N-Heptan或者 Exxsol D40。具有以下检测功能:

·         动态流量检测,单位为 mg/inj (体积和重量测量),用来喷射器线性的计算


静态流量检测,单位为g/s (体积和重量测量)

  • 开启和关闭时间的确定
  • 线圈阻力和线圈电感的确定
  • 绝缘电阻的确定
  • 抗压强度的检测
  • 阀底座泄漏的确定
  • 喷射的光学分析(喷射密度,轴向和径向的喷射尺寸)




Calibration Line for GDI Injectors

This production line is an automatic system for calibration, test and final assembly of high-pressure solenoid fuel injectors.
It is a fully automatic line and able to perform the following  process steps:

    • Run-in with a functional check of the injector
    • Calibration of the dynamic flow
    • Measurement of static and dynamic flows with different  driver parameters
    • Measurement of spray geometry
    • Liquid leak test
    • Blow out
    • Filter assembly
    • Combustion seal assembly
    • Optical connector-pin check
    • Washer and snap-ring assembly

The system is automatically loaded by a central robot combined with a conveyor system which connects the calibration modules. The line consists of several calibration modules with equal functionality and one assembly module. If one calibration module needs to be stopped (e.g. for maintenance), the line will continue producing with less efficiency.

Flow Test & EDM Loader for GDI Valve Seats

The machine has been designed for fully automatic on- and offloading of 2 EMD machines as well as for type recognition and flow measurement of EDM processed nozzle components for gasoline direct injection.
The blank parts are transported to the camera station (used for type recognition) by bowl feeder. The robot distributes the parts between the external EDM machines and a rotary table. The rotary table distributes the parts to the following stations:

  • Flow measurement station
  • Air purge station


The flow tested parts are put into several classified offload boxes.

Sonplas GmbH- Sachsenring 57 - D-94315 Straubing - Deutschland - Tel: +49 (0) 94 21 / 92 75 - 0 Fax: +49 (0) 94 21 / 92 75 199 - info(at)

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