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EDM HEG Gas Needle

The automatic HE grinding module is used for the flow calibration of injection components. Based on a rotary table concept, the workpieces pass through various processes in successive stations: Pre-measuring – HE grinding- Blowout – Flushing – Final measuring – Blowout. During the HE grinding process, an abrasive fluid is pumped under high pressure through the workpiece bores to round off. Depending on the application, the flow rate is increased by 8 % - 30 %. The grinding process is stopped as soon as the correlated desired flow value has been reached.
The loading and unloading of the module is carried out automatically by a 4-axis robot which grips the workpieces from pallets and inserts them into the rotary table.
For safe pallet detection, the DMC code is read in on the pallets by means of a DMC camera and the dot code on the workpieces is also read in by means of a camera for part detection and for seamless data traceability. The module has a swiveling control panel with a comfortable user interface. Processes and their results are clearly visualized. In the case of modified processing and test requirements, a quick adjustment of the parameters is easily possible.


Rotary table for HE grinding of valve seat

The fully automated HE-grinding module is used for the flow calibration of fuel injection components. Based on a round table concept  the workpieces pass through the individual processes. At the HE-grinding process an abrasive fluid is pumped under high pressure through the workpiece holes to round them. The flow increases, depending on the application, from 10% to 35%.The grinding process is stopped as soon as the correlated target flow has been reached.

• DMC station: The robot takes the component above the camera to read the data matrix code of the component (serial number).
• Loading round table: Transfer point from robot to round table an vice versa.
• Pre-measuring station: Here, the flow quality of the preliminary process is checked (within the specified flow tolerance).
• Grinding station 1: Rounding process of the component (can be used for pregrinding but also for final grinding).
• Washing station 1: Cleaning process after grinding.
• Grinding station 2: Rounding process used as final grinding to the target flow.
• Washing station 2: Cleaning process after grinding.
• Measuring station 2: Verification of the flow quality after grinding (within the specified flow tolerance)
• Blow out station: Drying process (free part from oil residues)


Rotary Table for HE-Grinding

The semi-automatic HE-grinding (hydro erosive grinding) module has been designed for flow calibration of diesel injection components to a defined target. Based on a rotary table concept the workpieces are processed in sequentially arranged stations of this module – HE-grinding, purging, measuring. The stations are integrated twice to work on different holes in one pass. During the grinding process an abrasive fluid is pumped through the orifices of the workpieces in order to radius bore hole intersections.
The flow will be increased by 8% - 30% depending on the process. The grinding process is stopped as soon as the flow has reached the correlated target flow value.
The loading and unloading of the module takes place manually. This procedure is also possible from two sides simultaneously. A moveable control panel with a comfortable user interface is installed. Running processes and results are displayed. The parameters can be easily adjusted in case of changing requirements.

HE-Grinding bench

The semi-automatic hydroerosive grinding module has been designed for flow calibration of high-pressure injection components to a defined target. The single station is thereby loaded manually by the operator. During the grinding process an abrasive fluid is pumped through the orifices of the work pieces in order to radius bore hole intersections.
The flow will be increased and stopped as soon as the flow has reached the correlated target flow value. A moveable control panel with a comfortable user interface is installed. Part data can be entered by a DMC scanner. Running processes and results are displayed. The parameters can be easily adjusted in case of changing requirements.


HE-Grinder

The semi-automatic hydro erosive grinding module has been designed for flow calibration of high-pressure injection components to a defined target. Based on a rotary table concept the workpieces are processed in sequentially arranged stations of this module: grinding, flushing, measuring.

During the grinding process an abrasive fluid is pumped through the orifices of the workpieces in order to radius bore hole intersections. The flow will be increased and stopped as soon as the flow has reached the correlated target flow value.

A moveable control panel with a comfortable user interface is installed. Running processes and results are displayed. The parameters can be easily adjusted in case of changing requirements.


高压液压挤压研磨加工喷油嘴设备

 

在柴油喷油嘴的生产中,必须通过一种特殊的高压液体研磨方法来调节喷油孔的流量。在研磨过程中,高压液体泵入到油嘴喷孔处。利用一种特殊结构的气缸泵(Sonplas公司专利的“Active Flow Meter“ 方法 )产生一个恒定,确定的液体流量通过喷油嘴工件。喷油嘴工件对此的反应是,在开始阶段,因为所通过的流量阻力很大,就会产生阻力背压,它要大于正常压力值。当喷孔的入口边缘随着加工过程,逐渐被倒圆后,这个压力也就会逐渐降低,因此流量阻力减小。当通过喷油嘴工件的研磨压力达到设定值时,这个研磨加工过程就会自动停止。设备采用模块化设计,按照要求,可以最多由3套平行工作的回转工作台组成,它们由一个共有的上下料系统提供服务。

液体挤压研磨设备 I

 

该自动化研磨设备用于对高压喷射部件的流量研磨加工及校准。加工工件依次在回转工作台上通过以下工位:预测量,液体研磨,吹气 1, 清洗,再测量,吹气2。在研磨加工过程中,为了实现对喷孔边缘处进行倒圆加工,高压油泵将一种特殊研磨液体泵入工件孔内腔。经过液体研磨加工后,液体流量值一般会提高8% - 50%。当研磨加工达到所设定流量值时,研磨加工就会结束。设备上配置有机械手全自动上下料部件,将工件从托盘中取出并放置到回转工作台上。为了保证对零件的识别以及可靠的检测数据跟踪,将通过照相系统对零件上的二维码进行读取。设备配置有一套舒适操作工作台以及显示界面,加工运行过程及其结果将随时在操作界面上进行显示。当需要对加工和检测程序进行修改时,系统功能可以迅速满足要求。

HE grinding station

 

用此设备可以对喷油嘴工件喷孔入口边缘进行倒圆孔加工并去除孔加工产生的切边毛刺。对于研磨加工倒圆过程来说,使用一种配有研磨粉的混合液体在高压作用下泵入喷油嘴工件中。通过油液研磨粉混合乳剂的研磨作用,在孔上的边缘处进行倒圆,直到达到预先设置好的液体流量时,加工过程就会自动停止。研磨加工过程结束后,将对研磨夹具中的工件吹气和清洁处理。如果使用高粘度的研磨介质(最大粘度范围是64的液压油),工件的最大流量可达到 25 l/min。设备采用半自动配置,零件由操作者手动进行上下料。当按下开始扭后,设备将自动进行加工全过程。不同零件的加工可通过更换夹具部件来实现。在供应配件中所包含了全部用户零件所需的夹具部件。

液体挤压研磨倒圆角设备

 

该设备采用全自动操作配置,用于对喷油嘴喷孔倒圆角加工以及流量校准的液体研磨加工。设备设计成回转工作台结构,工件从研磨工位开始,依次通过清洗,吹气,检测,最后再次吹入干燥压缩气体。加工工件通过零件处理机构放入设备中并取出。为了实现对喷孔边缘处进行倒圆加工,高压油泵将一种特殊研磨液体泵入工件孔内腔。借助液体研磨方法去除喷孔处的毛刺(这是之前加工工序中产生的)。经过液体研磨加工后,液体流量值一般会提高10%。当研磨加工达到所设定流量值时,研磨加工就会结束。工件上下料采用手动完成,设备配置有一套舒适操作工作台以及显示界面,加工运行过程及其结果将随时在操作界面上进行显示。当需要对加工和检测程序进行修改时,系统功能可以迅速满足要求。

液体挤压研磨及流量检测设备

 

该设备通过一种特殊的高压液体研磨方法来调节喷油孔的流量。在研磨过程中,高压液体泵入到油嘴喷孔处。利用一种特殊结构的气缸泵(Sonplas公司专利的“Active Flow Meter“ 方法 )产生一个恒定,确定的液体流量通过喷油嘴工件。喷油嘴工件对此的反应是,在开始阶段,因为所通过的流量阻力很大,就会产生阻力背压,它要大于正常压力值。当喷孔的入口边缘随着加工过程,逐渐被倒圆后,这个压力也就会逐渐降低,因此流量阻力减小。当通过喷油嘴工件的研磨压力达到设定值时,这个研磨加工过程就会自动停止。液体挤压研磨过程完成后,工件在另外的冲洗工位进行清洁。设备还包含有一套液体流量检测工位,对研磨加工后的零件进行流量检测。设备所配置的不同加工及检测工位可以相互不干扰独立工作。

喷油嘴工件液体挤压研磨设备

 

在柴油喷油嘴的生产中,必须通过一种特殊的高压液体研磨方法来调节喷油孔的流量。在研磨过程中,高压液体泵入到油嘴喷孔处。利用一种特殊结构的气缸泵(Sonplas公司专利的“Active Flow Meter“ 方法 )产生一个恒定,确定的液体流量通过喷油嘴工件。喷油嘴工件对此的反应是,在开始阶段,因为所通过的流量阻力很大,就会产生阻力背压,它要大于正常压力值。当喷孔的入口边缘随着加工过程,逐渐被倒圆后,这个压力也就会逐渐降低,因此流量阻力减小。当通过喷油嘴工件的研磨压力达到设定值时,这个研磨加工过程就会自动停止。设备采用模块化设计,按照要求,可以最多由3套平行工作的回转工作台组成,它们由一个共有的上下料系统提供服务。

手动操作的液体挤压研磨设备

 

该设备通过一种特殊的高压液体研磨方法来调节喷油孔的流量。在研磨过程中,高压液体泵入到油嘴喷孔处。利用一种特殊结构的气缸泵(Sonplas公司专利的“Active Flow Meter“ 方法 )产生一个恒定,确定的液体流量通过喷油嘴工件。喷油嘴工件对此的反应是,在开始阶段,因为所通过的流量阻力很大,就会产生阻力背压,它要大于正常压力值。当喷孔的入口边缘随着加工过程,逐渐被倒圆后,这个压力也就会逐渐降低,因此流量阻力减小。当通过喷油嘴工件的研磨压力达到设定值时,这个研磨加工过程就会自动停止。液体挤压研磨过程完成后,工件在另外的冲洗工位进行清洁。设备还包含有一套液体流量检测工位,对研磨加工后的零件进行流量检测。设备所配置的不同加工及检测工位可以相互不干扰独立工作。

Nozzle HE Grinding Machine

The automatic HE-grinding (hydro erosive grinding) module has been designed for flow calibration of high-pressure injection components to a defined flow target.
Based on a rotary table concept the work pieces are processed in sequentially arranged stations: HE-grinding 1 and HE-grinding 2 (different modes available), blow-off 1, purging, measurement, blow-off 2. During the grinding process an abrasive fluid is pumped through the orifices of the work pieces in order to radius bore hole intersections. The flow will be increased by 8 – 30% depending on the process. The grinding process is stopped as soon as the flow has reached the correlated target flow / target pressure value. The loading and offloading is done by a 3-axis-robot taking the work pieces out of the pallets and putting into the rotary table. For 100% data traceability the dot matrix code is detected on the work pieces by means of a camera.

 

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)sonplas.de

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