HE-Grinding Plant

The semi-automatic hydro erosive 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. Running processes and results are displayed. The parameters can be easily adjusted in case of changing requirements.

Diesel Injector Flow Test and Spray Test

Test of Diesel-Piezo-Injectors under variable test conditions. The injected mass quantity can be measured as well as the lower and side spray picture, wherein the characteristic angles and the shape of each single spray can be evaluated.
With the Windows-based user-interface for automatic, manual mode and process parameterization the usage of the bench is very easy and intuitive.

Injector Test Bench DI/Gas

The manual loaded test bench is used for precise measurement of Injection Systems.
Test conditions are very variable.
In the three stations it is possible to measure precisely the injection rate, rail pressure, rail
temperature and the injection mas shot to shot.

Injector Test Bench

The machine is equipped with two similar test stations. Each station evaluates a wide range of values that are characteristic for a diesel injector by use of a shot to shot measurement device.
The test sequence starts after the operator has inserted an injector into the text fixture. The selected testplan contains the test sequence as well as the targets and limits of each attribute. The sequence is defined by a number of single test points. The main difference between the single points are the system pressure and the injector opening time.
During each test point a various number of results (e.g. system pressure, injector rate, opening and closing time, backleak pressure and backleak flowrate) are collected, evaluated and stored in the database of the machine.
At the end of the cycle the machine evaluates all attributes and displays the result to the operator.

Flow Test Benches for combined Diesel-/Gas injectors

The test benches are designed to determine characteristic flow values and injection rates of combined Diesel/Gas injectors. There are two test benches, one for testing the diesel side, the other one for testing the gas side of the injector. The injector is loaded manually in an onload station which is protected by safety doors.
An automated part handling loads the injector into the test station. The parameterizable test starts after the hydraulic and electric clamping of the injector. After the test has been finished, the injector will be unloaded analogous to the loading of the injector..

NNC Assembly Line

Fully automatic injector assembly.
The individual parts of the injector are fed by pallets on a conveying system of the machine.
The installation is fully automated by three robot systems. To compensate the variation of the items all the relevant dimensions are controlled by integrated measuring stations and observed during the assembly.
This guarantees a constant output quality.

Injector fine adjustment

The mainly manually Station is used to measure and adjust the open and closetime of diesel injectors.
The Injectors are manually loaded, manually adjust, and manually released.
The measurement and calculation of the open and closetime and the calculation of the adjustment angle is fully automated.
The serial number is recorded by a Camera.
Parameters like set point, measurement time and maximum time to read the code are changeable.
The most parameters can also be set in a test plan.
The open and closetime is measured by a Nation Insruments card with a Sampling rate of 25 M samples per second. Due to the high resolution, exact results are possible.

Backleak test bench

This test bench tests the back leakage from a component of a diesel fuel injector. Leak flow is an indicator of the quality of the guide gap. Precise measurement of the guide gap is used to classify the test part quality and to provide feed back for adjusting the production process upstream. An Active Flow Meter (AFM) creates the pressure required for testing. Flow measurement is also done by the AFM. A variety of test plans and manual test part feed means that quality control measurements and tests can be carried out in a very short time. With automatic test part feed, the back leak tester has a cycle time of less than 30 seconds at a wide pressure range. Set point pressures up to 300 bar can be reached within 7 seconds. All the measurement data can be easily imported into the tables customarily used for calculations and data processing.

Robot loader for 2 EDM machines

The loader serves for fully automatic loading and unloading of 2 EDM machines with integrated flow measurement of finished parts. The parts are delivered to the robot cell by means of two drawers. One robot distributes the parts to the erosion machines, measuring station and conserving system. After conserving the IO parts are again deposited in the drawers. The NIO parts are transported to a box.

Nozzle Orientation System

This machine has been designed for orientation of nozzle bodies which do not have any dowel holes. Injector body, nozzle body and retainer have to be assembled. By means of a vision control system the machine orientates the nozzle body to the injector body by defined spray hole angle. Retainer and injector body are screwed together by controlled torque and angle. After the assembly process, the spray hole angle is measured again.

Manual Flow Stand

The test bench has been designed for the determination of the static flow of diesel injection components. The operator holds the part in front of the camera that reads the DMC of the part. The testplan is selected automatically by using the part number of the work piece. Thereafter the part is loaded into the measuring station. The operator start the process by pressing the two-hand start button. After the measurement the part is blown off.

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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