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Rail Assembly Line

The assembly and test plant exists of 6 processing station. The loading of the rails is done with an handling system. The tape system will feed then the roboter with rails which will be inserted in the identify station. There the rail gets an serial number. After that the RPS and PCV will be screwed to the rail. The next process is to test those sensor and valve and to make an pressure drop test. Next the rail will be washed and finally there is an optical inspection of the rail.

Common Rail Flow Test Bench

The bench measures the flow of automotive common rails at a controlled pressure, back pressure and temperature. Each borehole is tested step by step in both directions. A conclusion on the bore quality is possible by calculating the ratio of flow and reverse flow. The loading and unloading of the bench is carried out manually. The datamatrix code is read with a fix installed camera system. The results are sent to a customer specific database after finish of all selected steps in the test plan. The test bench has a quick exchangeable work piece carrier and is set up for rails up to four cylinders. With the calibration equipment (accessories kit) the calibration of the bench can be monitored. It measures the pressure, the temperature and the mass flow. Additionally, a balance is installed to observe the flow gravimetrically. This is done by directing the test fluid in a tank with a time controlled valve.

Jet Test Bench

The bench is used to measure so called jets. Jets are small nozzles which are inserted in the rail of common-rail diesel motors to throttle the flow to the injectors. The five nests on the rotary table are manually loaded. They can be loaded partly or completely in any sequence, but with defined direction. After pressing the start button the amount and position of the inserted jets is checked. Jets in wrong direction are ejected and the sequence is stopped. After start with correct placement, the rotary table moves jet after jet through the measuring station, where the flow is measured at constant supply and back pressure. The flow direction is set in the test plan. When the measurement is finished the jets are transported to the front side and are ejected. The results of the jets are clearly displayed in columns on the screen.

Rail Test Bench

The test bench is used to measure rails for automobile diesel motors. The flow through the rail is measured in various directions at constant supply and back pressure. The circular rail (see picture) or linear rail is manually clamped onto the changeable pallet, the barcode of the rails pressure sensors is scanned. By pressing the two-hand-start button the rotary table rotates and the lift door in the middle of the bench closes. At the backside of the bench the pallet with the rail is contacted with a hydraulic multi coupling and is measured. While the test is running at the backside the next rail can be clamped at the front.

HPS Rail Assembly & Test Machine

The machine has been designed for assembling a HPS
(high pressure sensor) to a diesel common rail. After the assembly a HPS voltage test at different pressure values is carried out. Up to five test points are configurable.
After the HPS voltage test a pressure drop test is performed. The pressure drop test is also adjustable in time and pressure value. At the end of a cycle the rail is blown out with pressurized air (up to 10 bar).
The bench is realized as semi automatic machine with manual on- and offload and automatic test run.

Common Rail Solvent Drying Machine

The autartical machine, treats Rails in different steps, by cleaning the surface and also cleaning the inner parts from residues caused from former processes.  
The bench is realized as a fully automated machine with manual loading and unloading of the Rails.
- Shaking : Shaking of the rail to remove oil residue inside of the pressure sensor Additional air blowing for rough external surface drying
- Solvent spraying on external surface Solvent spraying on the surface of the Rails with nozzles Internal drying of the Rails with vacuum and air blowing
- Air blowing of the surface: Blowing of the external surface from dissolved oil residue and remaining solvent
- Air blowing of problematic areas: Air blowing of difficult to access areas of the rails by flexibel to adjust nozzles. The internal transport of the Rails is done by a fully automated rotary table handling.

Calibration Bench

Calibration bench for inspection of pressure, flow and temperature of the Sonplas rail and jet test benches. The bench mainly consists of the moveable aluminium base frame where pressure gauge, flowmeter and temperature gauge are installed. The connection to the inspected bench are self closing couplings, whereby the calibration bench is included into the test fluid cycle.

 

Rail Audit Flow Control Bench

The bench measures the flow of automotive common rails at a
controlled pressure, back pressure and temperature.

Each borehole is tested step by step in both directions. A conclusion
on the bore quality is possible by calculating the ratio of flow
and reverse flow.


The loading and unloading of the bench is carried out manually. A fix installed tag reader is used to read the serial number of the part.


The results are sent to a customer specific database after finish of all selected steps in the test plan. The construction of test bench allows using quick exchangeable work piece carriers.


The test bench is set up for rails up to four cylinders.

 

 

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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