Nozzle Function Test Bench

The bench has been designed to determine the following characteristic values:

• Nozzle Opening Pressure (NOP) in dependence of the applied needle force and supplied constant flow
• Spray test of nozzle; determination of the amount of single jets
• Volume flow
• Volumetric determination of back leakage
• Optical determination of seat leakage

The needle force needed for the different tests is built-up hydraulically and monitored by a pressure sensor. Servo motoric driven high pressure pumps generate the constant flow for the tests. The pumps are located near the test heads.
The parts are loaded manually into a rotary table with sixfold division. This table handles the transport of the parts through the whole machine. At the last station, after all tests have been finished, the part is unloaded by a pick and place handling from the rotary table via a railing system.

Nozzle Function Test

This fully automatic machine can test injection nozzles regarding their flow and tightness.

This is done with following working steps:
• Reading and checking (with customer process data system) of the three part DMC’s
• Inserting the parts in the round table
• Purging / flushing
• Assembly
• Check of tightness (backleak and wet seat)
• Flow measurement
• Disassembly.

Faulty parts are split up into error classes and are discharged in pallets.


EDM Loader and Flow Test for Nozzle Bodies

The fully automatic flow test bench is loaded by a robot. There are drawers for 4 pallets (2 pallets for each EDM machine. 1 pallet for loading and 1 pallet for unloading).
The Sonplas machine is located between two EDM machines. The nozzles are automatically loaded from the pallets and positioned in front of the camera which checks the data matrix code. Thereafter, the blanks are loaded onto the respective EDM machine shuttle. The eroded nozzles are removed from the shuttles and are taken to the rotary table. If needed, the nozzles can be turned by a turning station.
The rotary table includes a blow out station and a measurement station. The measured nozzles are loaded back into the respective pallet for unloading. Reject parts are dropped into scrap boxes or two suspect rails. Production results are stored in a database. The test plans, in which the different parameters are stored, are also located in the database and can be edited by the user. All flow test results are being sent to the respective EDM machine for production quality optimization.

Opening Pressure Test Bench

The opening pressure test bench has been designed for the determination of the opening pressure. The operator inserts the nozzle manually in the lifter of the camera.
When the operator gets out of the inner side of the machine, it starts automatically and closes the protection door, reads the DMC code and the nozzle moves into the station where it is contacted and the measurement process starts. The needle force, which directly affects onto the needle, is generated by the media pressure built up by a servo-driven plunger pump and steplessly adjustable.
The required constant flow is generated by a second servo motor controlled pump which is mounted also next to the test head.

Function Test Machine

The test bench has been designed for the determination of the following nozzle characteristics:

• opening pressure
• spray geometry
• seat leak
• back leak

The operator inserts the nozzle manually into the nest whereby the nozzle is orientated to its high-pressure bores. A calibration fixture inside of the test head enables an infinitely variable adjustment of the spring force load on the nozzle needle, which is supervised by a force sensor. By actuating the start button the guard door is closed automatically and the test sequence begins. The required constant flow is generated by a servo motor controlled pump which is mounted next to the test head.

Flushing and Lift Control FVC-RT6

This automatic module flushes nozzles and needles. After assembling both components the lift between both parts are measured. On- and offload are handled by a 4-axis robot. For the part control the DMC of each part is read in the loader module.
Nozzle and needle are loaded into the machine on a pallet by means of a conveyor.
On the machine the parts will be demagnetized. The robot catches both parts and takes them to the DMX reading station. After reading the parts are placed into the rotation table. The following work steps are carried out in the stations:

Station 1: On-/offload by a robot
Station 2: Turnover of the nozzle body
Station 3: Flushing the nozzle body
Station 4: Flushing the needle
Station 5: Assembly of needle and nozzle
Station 6: Measuring the lift

After these work steps the components are loaded onto the output conveyors.
The module contains a rotatable HMI. All processes and actions are displayed on the HMI.
It is also possible to change the settings and parameters on the HMI panel.

Vout Test Machine FT-RT4

The test bench has been designed for static flow measurements of diesel injector components.
The components can be measured with or without back pressure.
The machine is equipped with a rotary table which enables two simultaneous processes.
As a result, the loading and unloading (with reading) of Dot-Code can be done in parallel to the test
procedure. Data are stored as a file on the local hard disc as well as on the customer database.

High-pressure Test Bench

The test bench can measure nozzles with and without needle using different adapters.
The test with needle can be done by fixed stop or by automatic needle lift adjustment.
The automatic needle lift allows the bench to measure characteristic lines. The supply pressure
can be up to 2400 bar depending on the current flow.
In addition, a counter pressure up to 340 bar can be used. The clamping force is adjusted to the respective supply pressure.
The parameters of the measurement are managed by test plans.








  • DMC二维码数据读取
  • 光学照相方法检测油嘴偶件座面密封性能(体积流量法 以及/或者 像素分析法)
  • 油嘴偶件径部间隙泄漏检测(体积流量法 和/或者 降压检测法)
  • 喷油嘴体及油针的分离





  • 喷油嘴的流量检测
  • 试验台配置有两套独立的测量循环系统
  • 通过机械手实现在两个测量工位上自动化装载工件
  • 配置有喷油嘴DMC二维码读取器
  • 可以将不合格工件分组放置在5个不同的

Nozzle Final Flow Test

The test rig is designed for the determination of the static flow of diesel injection nozzles including matched needles. Fixed or variable needle lift is possible.


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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