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Fuel Pump Characterization Test Stand

The ATEX-conform characterisation bench is designed for the characterisation of all functional parameters of automotive fuel pumps according to AK-LH15/16 . Test conditions like temperature, fuel and vessel pressure or fuel volume can be varied in wide ranges.
All common fuel types and mixtures can be used.
The test bench is able to run EC and DC pump types and allows to set a lot of el. control parameters like voltage, PWM signal frequency, PWM signal amplitude, PWM duty cycle.

A multiplicity of sensor signals can be recorded and stored in a result file. Some selected signals can be recorded with a fast acquisition frequency.
The measuring of voltage, current and power consumption is performed with a high-precision power analyser.

The duty cycle of the PWM signal for the pump controller is generated by a Sonplas developed electronic board. Test routines are programmed by using a  Flexible Test Plan Software, allowing the validation engineers a maximum flexibility in creating individual test sequences.

Endurance GDI Pump Test Bench

This endurance test bench with two separate stations has been designed for different kinds of high-pressure gasoline injection pumps.
The test fuel and lubrication oil supply is fully integrated in the test bench. Temperatures and tank levels are continuously monitored. After editing the testplan in “SonDaSys-Flex Testplan”, it is possible to choose each station separately, as well as to start, stop and interrupt
each station. During the test, pressure, rotation speed, torque, temperature and flow are monitored and recorded.
The successful test is finished after a defined testing time. If an error occurs during the test, only the specific station will shut down and detailed information (analog values and information text) are stored. Thus, trouble shooting and diagnostics are easy to perform. For this reason a free configurable ring buffer is implemented, which stores the last minutes.
This information can be visualized.

GDI Pump Test Bench

The machine offers a fully automatic testing of cam-driven highpressure fuel pumps.
The mechanic drive and the low- and highpressure proof circuit are simulated by the test bench. The test devices are automatically supplied to the machine by a conveyor system. Inside the test bench a gripper handling is used for the transport of the pumps. There is also a camera for detection of the serial numbers of the pumps. The test is carried out in the
measurement station.
The automatic contacting of the test device inside the machine takes place on an easy changeable workpiece carrier. The changeover to a different pump type happens by changing this pump-specific workpiece carrier. Hereby, a high flexibility of the test bench to different geometries of the low-and high-pressure connector and to the electrical contacting of the test device is assured.
The test parameters are adjusted through a data based flexible test plan system.The individual test steps can be positioned in any order and number and with different set point limits.
By means of the central database on a separate server PC it is possible to easily connect several test benches of the same type. All results are automatically stored and archived on the server.

GDI Pump Assembly / Testing Line

The machine is used for the completion of pumps after they have left the pump test stand.
In the first station they are blown out once more to reduce the residual oil level. In the
second station the O-ring is installed with help of an operator. In the third station the parts are marked with all necessary information by means of a laser. Followed by the fourth station, which verifies the labelling and other criteria of the pump by a camera system.
This is followed by the last station where an operator is able to mount the caps and, upon successful testing with a further camera system, releases them for packaging.
If a characteristic falls out of the tolerances during the test, these pumps will be transported to a separate reworking belt, where they can then be reworked and reintroduced for a new test.

GDI Pump Pre-assembly

The module has been designed for the assembly and the leak test of sealing caps.
The supply of the single parts are effected by means of a bowl feeder. The parts are assembled position or force regulated with a press.
During the pressing process the force is supervised in order to detect error parts. The assembled parts are tested in a leak test station to check the leak tightness. The checked parts are placed on a pallet which is removed by a belt system from the module.

GHP 2.X Assembly Multiflex

By means of the fully automatic production line single-piston gasoline pumps are assembled. The processing stations have been designed as individual single, double and roundtable
stations. The components required for installation are manually inserted.
The process spectrum ranges from servo presses for pressing, crimping and way measuring, laser welder for the welding of different parts, camera applications for part inspection and
measurement up to adjusting overpressure valve. The sometimes extensive measurement and production results are transmitted to the line's own database and customer database for more precise tracking.<
The targets and limits for the various production steps are stored in the database which can
be adapted to the test plan program at any time.

Calibration Bench PRV Micro Hammer

This calibration stand has been developed for a highly precise opening pressure adjustment of the mechanical pressure relief valves in high-pressure pumps.
When adjusting the opening pressure many mechanical manufacturing tolerances play an important role by conventional methods and thus increase the scattering. By the direct measurement of the opening pressure during the calibration process in combination with a very precise positioning manufacturing, tolerances are eliminated and an opening pressure setting with minimal tolerances is possible . The workpieces are manually inserted into the test device.

Pump test bench EC/DC

The fuel pumps are to be tested for use in motor vehicles of many well-known automobile manufacturers. Before delivery, a test with fuel replacement medium (test fuel) is performed.
This ensures that the pumps meet their specified characteristics.

Dual Test Bench EOL for GHP Pump

The machine offers a full automatic testing of cam-driven high pressure fuel pumps.
The mechanic drive and the low- and highpressure proof-circuit are simulated by the test bench.
The test devices are manually supplied to the machine. Inside the test bench a gripper handling is used for the transport of the pumps. There is also a camera for detection of the serial
numbers of the pumps. The test is carried out in two independent working stations.
The automatic contacting of the test device inside the machine takes place on an easy changeable workpiece carrier. The changeover to a different pump type happens by changing of this pump-specific workpiece carrier. Hereby a high flexibility of the test bench to different geometries of the low-and high-pressure connector and to the electrical contacting of the test device is assured. Sliding protection separations of the stations allow to run a half machine in production mode during maintenance works.
The test parameters are adjusted through a data-based flexible test plan system.
The individual test steps can be positioned in any order and number and with different set-point limits. By means of the central data base on a separate server-PC it is possible to easily connect several test benches of the same type. On the server all results are automatically stored and archived.

Inlet Valve Subassembly

Automatic assembly of the inlet valve for a high pressure gasoline pump with the following
substations:

• Loading robots for the raw material
• Station for joining the components with camera check
• Laser welding station
• Stroketest station
• Leckagetest station
• Robot for unloading the finished inlet valves.

Damper Subassembly

Assembly machine for subassembly group „damper“ of a gasoline high-pressure pump,
consisting of:

• Filter press in station
• Manual on-/offload by an operator, secured by a light curtain
• Station for filter check
• Bowlfeeder for feeding machine with material „accumulator“ and „cover“
• Cover press-in station
• Laser welding station.

Spill Valve Subassembly

[Fully automatic assembly station for the component “spillvalve” of a gasoline high-pressure pump, consisting of:

- 2 on/offload robots
- 2 laser welding stations
- runout measurement station
- cutoff station.

The raw material is loaded into the machine via bowlfeeder or pallets in drawers.

GDI Pump Test Bench

The test bench has been designed for testing of gasoline high pressure pumps.
Their characteristics are essentially defined by the integrated analog and digital volume control valve (VCV). The test bench measures the flow capacity and the operating pressure of the pump depending on the supply pressure, rotation speed, test fuel temperature, high-pressure
and the adjusted VCV current or rather the time control of the digital VCV according to the bottom dead center.
The test bench has got two similar stations. The stations have got separate and individual fluid circles. This test bench is a semi-automatic machine with automatic test and manual loading and off-loading. The test bench must be filled with Exxsol.

Capacitor Discharge Welding Bench

The manually loaded bench welds components by capacitor discharge technology. The part check and the process state is done by vacuum sensors.
The single parts are automatically checked, assembled and transported to the welding station. Before the parts are welded, the contact presses on the parts and the highly dynamic water
cooled cylinder regulates the force. At the same time, the welding capacitor is loading up to the welding voltage.
After the force is stable, the welding impulse will ignite. The set points and limits are managed by a database system.

End of Line Pump Test Bench

The machine offers a full automatic testing of cam-driven high pressure fuel pumps. The mechanic drive and the low- and highpressure proof-circuit are simulated by the test bench.
The test devices are supplied to the machine by hand. Inside the test bench a gripper handling is used for the transport of the pumps. There is also a camera for detection of the serial numbers of the pumps.
The automatic contacting of the test device inside the machine takes place on an easy to change workpiece carrier. The changeover to a different pump type happens by changing of this pump-specific workpiece carrier. Hereby it is assured a high flexibility of the test bench to different geometries of the low-and high-pressure connector and to the electrical contacting of the test device. The proof parameters are adjusted through a data-based flexible proof-plan-system. The individual proof steps can be positioned in any order and number and with different set-point limits.
Thanks to the central data base on a separate server-PC it is possible to easily connect several test benches of the same type. On the server all results are automatically stored and archived.

Universal GDI Pump Test Bench

The machine offers a fully automatic testing of cam-driven high- pressure fuel pumps.
The mechanic drive and the lowand high-pressure proof circuit are simulated by the test
bench. The DUT’s are supplied to the machine by hand or by robot parallel to the test cycle. Inside the test bench a gripper handling is used for the transport of the pumps.
There is also a camera for detection of the serial numbers of the pumps. The automatic contacting of the test device inside the machine takes place on an easy-to-change workpiece carrier. The changeover to a different pump type happens by changing this pump-specific workpiece carrier. Hereby, a high flexibility of the test bench is assured to different geometries of the lowand high-pressure connector and to the electrical contacting of the test device.
The proof parameters are adjusted through a data-based flexible proof-plan-system.
The individual proof steps can be positioned in any order and number and with different set-point limits. The test results are collected in a central data base and transferred into the customer network.

Functional Test Bench Gasoline Pump

This system has been designed for testing fuel high pressure pumps with gasoline at different ambient- and fluid temperatures. The test bench simulates the mechanical drive, supply- and high pressure circuits. It measures the flow capacity or the operating pressure dependent on supply pressure, rotation frequency of the pump, ambient- and fluid temperature, high pressure and the volume control valve (VCV).
The test bench has been designed for manual loading and unloading and automatic test sequence, predefined by a flexible test plan. Manual operations and measurements are possible as well.

 

Fuel Pump Durability Test Stand

 

The ATEX-conform test stand has been developed for the durability test of electrical fuel intank pumps (DC/AC-pumps) according to AK-LH 15/16.
Up to 10 pumps or pump modules can be installed and tested in the fuel tank. Within this test it is possible to vary the supply voltage, pump rotation speed, fuel pressure and temperature.
The integrated flow measurement with valve matrix is able to measure periodically the flow of each pump. Furthermore, voltage, current and pressure for each pump are measured during the test, as well as the fuel temperature in the tank.
The fuel circuit is designed to run with all common fuels like gasoil, gasoline, ethanol and blends.
Test routines are programmed by using a  Flexible Test Plan Software, allowing the validation engineers a maximum flexibility in creating individual test sequences.

 

Pump Test Bench

 

This test bench has been designed for testing screw pumps which are used for fuel supply.
The pumps are inserted manually into pallets. The stations are loaded completely automatically by means of a robot.
First, the orientation of the screws are verified and an optionally existing data matrix code is read.
In order to reduce the cycle time two pumps can be tested simultaneously in both test stations.
The pumps are driven by a servo motor and supplied with tempered test oil via an elevated tank by means of gravity.
A defined pressure is regulated on the outlet side and the resulting flow rate is measured. Moreover, the mechanical drive power is determined by the measured signals rotation speed and torque.
Finally, a serial number is scribed onto the pump housing by means of a marking system.
The pumps are conserved with anti-rust oil.
Good pumps are inserted into the pallet again, whereas scrap pumps are separated according to their failures and are inserted into the corresponding scrap lines.

 

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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