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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.

 

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 of diesel injection nozzles

The test bench has been designed for the determination of the static flow of diesel injection nozzles. It is placed between two EDM machines and is designed as semiautomatic rotary table machine. The operator loads the nozzles into the test bench through an opening at the front side and starts the test process. The rotary table comprises 2x4 nests for test parts as well as 2 nests for master parts. The desalinated water, which is used in the EDM process, is blown off in a blow out station before the flow test. After the measuring process the nozzle is blown off again. The nozzles are loaded off by means of a pick-and-place unit. Good and scrap parts are separated.

High Pressure Flow Test Bench

The test bench has been designed for the determination of the static flow of diesel injector components. It is possible to select between different test plans for different test components.

EDM Loader and Flow Test for Nozzle Bodies

The fully automated nozzle test bench is loaded and unloaded by a robot. There are drawers for 8 pallets: 4 pallets for each EDM machine (Sonplas system between two EDM machines). The nozzles are automatically loaded from the pallets and positioned in front of a camera which checks the data matrix code and nozzle geometry for orientation purposes. Thereafter, the blanks are loaded onto the respective EDM machine shuttle. Machined parts are removed from the shuttles and are taken to the transfer station which loads the rotary table with the eroded nozzles. The rotary table includes 4 stations: nest control, blow-out station, flow test station and the loading and unloading station. The measured nozzles are loaded back into the pallets. Rejected parts are dropped into scrap part boxes. Production results are stored in a database. With an integrated evaluation tool statistics and charts can be shown and printed. 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 will be sent to the respective EDM machine for production quality optimization.

 

Test bench for injection nozzles

 The plant is designed for determination of the following nozzle characteristics:

  • Opening pressure
  • Opening frequency
  • Spray geometry
  • Static flow
  • Optical seat leakage
  • Volumetric seat leakage

A robot inserts the supplied nozzles into a rotary dial. Three independent stations are mounted on the dial for measuring several characteristics of a nozzle. At the first station the nozzle is orientated in order to connect it to the medium supply at the following stations. At the second station the opening characteristics (opening pressure and opening frequency) and the constant flow are measured. At the last station the machine measures different types of leakages such as optical and volumetric seat leakage and the backleak of a nozzle by means of different methods (displaced volume and pressure decay). At the end of the process the robot sorts the processed parts and place them into scrap and passed trays respectively

 

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. 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 will be 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.

Flow test bench for nozzle elements and control parts

The test bench serves for measurement of the static flow rate of nozzle elements and control parts of injector components, especially for major diesel engines. The test bench is designed for flow test of various components by using adapters. All measured data can be imported in the usual table calculations without any problems.

 

Spray Visualization System

The Spray Visualisation System allows the verification of spray hole position and spray angles of diesel nozzles and is designed to control the EDM-drilling process. Therefore, the nozzle is clamped and aligned inside the test bench by a clamping fixture. This fixture rotates the nozzle and supplies it with fuel.
Two motor driven stages are moving the vision system components (camera and laser) precisely to calculated target positions. A high-resolution camera system is used to obtain highest measurement accuracy.
The system collects during a “dry” and a “wet” run images of each spray hole and spray beam and transfers these information into a virtual 3D coordinate system for the calculation of the following characteristics:

  •  Hole height at nozzle surface
  •  Hole spacing angle at nozzle surface
  •  Spray height angle
  •  Spray spacing angle
  •  Spray origin (option)
  •  Spray hole diameter (option)

Flow Test Bench

The test bench has been designed for the determination of the static flow of diesel injection nozzles with and without needle.

A moveable slider with two test part fixtures makes manual loading during a measurement process possible.

 A dedicated adapter orientates the nozzle and limits the needle lift. Changeable adapters for the test head and part fixture enable tests of other injection parts.


Flow and Spray Test Bench

The test bench is designed for the investigation of geometrical spray characteristics and flow measurements for injectors and nozzle elements. 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 radial backlight inspections and axial light sheet inspections. A motorized traversing system positions the axial light sheet optics. The nest rotation driven by means of a stepper motor allows a complete geometrical investigation of the spray characteristics.

HE-Grinding

The HE-grinding module has been designed for radiusing and deburring bore hole intersections. During the grinding process an abrasive fluid is pumped through the orifices of the work piece with high pressure. By means of the abrasive fluid, the inlet edges of the respective holes are radiused until the upstream flow or pressure of the nozzle has reached the nominal value. After the grinding process the work piece is cleaned with air.
The module is designed as semitautomatic machine. The operator loads and offloads the parts manually. The grinding process starts automatically after pressing the start button.
The machining of different parts is carried out by means of variable fixtures which have to be changed manually.


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)sonplas.de

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