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.


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.

Flow Test Bench

Test bench for static flow measuring of high flow injector components.
The wide flow range and the possibility to carry manifold adapters for the device under test give a high usage flexibility.
By means of the installed camera codes like DMC can be read in.
The data storage is done locally on hard disc and on the customer database.

Nozzle function test bench

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

- opening pressure
- opening frequency
- 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. The force to the needle is generated and controlled by a hydraulic circuit and via the fixture adapted to the test part . By actuating the start button the guard door will be closed automatically and the test sequence begins. The required constant flow is generated by a servo driven motor pump which is mounted next to the test head.

Flow Test Bench

The test bench has been designed for the determination of the static flow of injector components.
The machine will be manual loaded and started by the operator. Changeable adapters for the test head and part fixture enable tests of other injection parts.

High pressure nozzle flow rig

The test rig is designed to measure the static flow valve in and out incl. needle lift adjustment of diesel injection nozzles.
It is possible to do a flow test at an upstream pressure up to 1000 bar at a maximum flow of 10 liters per minute. Measurement with backpressure up to 170 bar will be also possible.
The machine is manually loaded with an automatic test sequence.

Nozzle function test

The machine is used to determine the following characteristics of nozzles:
Nozzle opening pressure (NOP), nozzle chattering behavior as a function of the automatically set needle downforce with constant flow
Determination of the back leakage (volumetric and / or pressure drop method)
Volumetric determination of wet seat leakage with a camera (optical)
The force on the nozzle needle is generated hydraulically. The force or pressure on the needle is monitored by a pressure sensor. The required constant flow is produced by means of a servo motor-driven pump, which sits in the immediate vicinity of the probe. The loading and unloading of the test parts is done manually.

Spray test bench

The bench is designed to measure the geometrical spray characteristics of a diesel injector in side and bottom view. Additionally, the injector’s opening and close time are  measured by means of an acceleration sensor, linked to a fast data acquisition board.
At the beginning of a test run the injector has to be placed manually into the rotating injector nest. Also the fuel and electrical connection has to be made manually.After the manual insertion of the injector into the test fixture, it will be automatically clamped by a hydraulic piston. All test conditions like fuel pressure, cavity pressure and fluid temperature are automatically set up by the bench. As soon as the machine reaches stable conditions, a first image will be taken from the bottom view camera to align one of the spray plumes perpendicular to the side view camera by rotating the injector nest. Now the measurements from the bottom  or side view camera can be taken.
During the image acquisition with the side view camera, a single spray plume will be separated from all other plumes by a special designed protection shield.
All evaluated results will be finally stored in a local database and some selected results will be sent to the customer database..


Nozzle Laser Marker

This machine is designed for the marking of nozzles. The machine moves in, moves out, depalletizes and palletizes the pallets fully automatically.
A robot takes out the nozzles and moves them to a camera. The camera calculates the rotation angle between current position and correct position of the pattern of drills.
Afterwards, the robot takes the parts to the rotary table where the parts are marked. The marking area is subdivided in several segments.
After the marking process, the well done lasered parts are returned to the pallet and the others are moved to the scrap part rail.

Flow Test Bench for Nozzle

The test bench has been designed for the determination of the static flow of diesel injection nozzles and inlet connectors. For each of the two test part types one manual loading measurement station exists with a common pressure supply and measurement circuit.
In the station of the inlet connectors it is possible to determine the flow in forward and backward direction. The DMC of the test part can be read manually by means of an integrated code scanner.


Wet seat and back leak test machine

The machine is used to determine the following characteristics of nozzles:

  • Reading of the Data Matrix Code
  • Optical measurement of the wet seat (volumetric and/or pixel)
  • Measurement of the back leak (volumetric and/or  pressure drop)
  • Disassembly of nozzle and needle


Loading / unloading is done automatically by a 3-axis scara robot that takes the parts from a tray and put them into the rotary table. Passed parts will be set back into the tray, scrap parts are sorted into error chutes.


Nozzle Valve In Flow Test

  • Flow measurement of diesel injector nozzle bodies
  • Two independent measuring circuits
  • Automatic loading of the measuring stations with robot
  • Reading of Data-Matrix-Code from the nozzles
  • Scrap parts are unloaded into five NIO-part rails.

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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