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.

Calibration trolley flow rate

This mobile system is designed for monitoring and calibration of flow rate sensors in existing test benches. The trolley has three flow rate sensors which are different in their measurement ranges. These sensors can be connected serially to the flow rate sensor which is to be calibrated by means of non-interchangeable quick couplings. In order to deaerate the measuring system, the lockable and adjustable pneumatic regulator as well as the waste tank with automatically controlled inlet valve can be used. The setting, controlling and handling of the test run are carried out by the integrated PC as well as the hand-held control panel. At the end of a test run a test report is created automatically.

VCV EOL – Calibration & Test Module

The test piece is a so-called VCV (Volumetric Control Valve)
which is a 3 way proportional valve. This is a component part of a high pressure injection pump and controls the gasoline inflow. This fully automatic production module calibrates the valves regarding their flow and pressure characteristics. To reach the requested cycle time the module consists of five identical calibration heads. After successful calibration, the VCV seat will be fixed by two laser welding dots. After passing all final tests a filter will be assembled and the VCV will be labeled with a laser marking unit. Passed parts will be separated to a conveyor, scrap parts to special fail lanes.

GDI pump test bench

The test bench has been designed for testing of gasoline highpressure pumps. Their characteristics are essentially defined by the integrated 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.
The test bench comprises two separate stations:
Station 1: Functional tests of the pumps
Station 2: Endurance test station

VCV Analysis Bench

The test bench has been designed for testing important characteristics of so-called VCVs (Volumetric Control Valve). The VCV is a 3-way proportional valve and part of a high pressure gasoline pump. The volumetric measurement is done by two selectable Coriolis flow meters with a different maximum range.
In general, the following test functions are available:


  • Flow and pressure measurement in dependence of the pressure and the electrical VCV drive settings.
  • Determination of flow and pressure hysteresis of the component.

The bench is realized as semi automatic machine with manual on- and offload and automatic test run.

HPPP endurance test bench

The 4-station test bench has been designed for endurance test of high-pressure petrol pumps (HPPP) of various sizes. The bench is supplied with fuel from a mobile tank trolley which is equipped with a centrifugal pump and a large stainless steel drip pan. The fuel tank temperature and level are monitored continuously. Once the test plan data have been entered, the stations can be selected and started individually. During the test, pressure, control signal and speed are time controlled to enable measurement of flow and temperature. The test ends when the preset total cycle time elapses. If a faulty test part is detected the system will be shutdown. All operations and every fault which occurs on the bench are recorded in an error log. This makes it possible to reconstruct the test cycle and to trace faults. For this purpose, the bench has a ring memory which records the last few minutes of the benches operation. The contents of this memory can be shown on a graphic display. The endurance test data are stored in an ASCII file and can be imported into spreadsheets.

Test bench for volumetric control valve

The volume flow control valve in the test bench is set at the flow setting point and subsequently checked for function. The operator places the test part into the nest. The correct position of the plug is ensured by a fork. The part is fixed by means of a suction unit. The part is automatically placed in the cavity after the station has been started. A clamping device presses the part down into the nest. Electric contact is made directly on the top of the clamping device by means of spring-loaded contacts. The valve is controlled by a power amplifier with parametrable current. A pressing arbour driven by a stepper motor moves the valve setting sleeve from below until the required flow is reached. Afterwards, following measurements will be performed:

  • Current ramp generation and recording of flow curve
  • Flow line assessment (limit values, hysteresis)
  • Leakage measurement

VCV Washing Benches

The test piece is a so-called VCV (Volumetric Control Valve) which is a
3-way proportional valve. This is a part of a high- pressure injection pump and controls the gasoline inlet flow. This fully automatic production module washes the high- pressure and low-pressure inlet of the VCV to remove contamination caused during the assembly of the VCV. The module also performs a run in process to the VCV. After the washing and run in process passed parts will be put back to the workpiece carrier, scrap parts will be moved to the scrap part lane. To reach the requested cycle time the module consists of five identical washing heads.

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)

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