deencn

Liquid Leak Test

Fuel injector quality is a decisive factor in the efficiency of motor vehicle engines. Sonplas has considerable experience in the design and construction of test benches for the leak testing of fuel injection valves.

The manually loaded test bench has been designed for different gasoline injectors. It offers high flexibility in testing injectors with different geometries due to a simple change of the injector fixtures and a single changeover dialogue in the software. The fully automated control software allows easy handling and high flexibility. Results and current values are displayed in the main window to guarantee an easy overview of the process.

 

Dry Calibration and Test of Gasoline Injectors

The automatic production line calibrates and tests PFI injectors.
A robot loads the injectors from pallets and puts them onto pucks at a conveyor system.
This conveyor connects all substations at the line.
The first substation at the conveyor is a code reading station where the part is identified.
After that, the parts are moved to the rotary table where the test substations are located.
Before the part arrives at the final dressing stations at the conveyor it can be transferred to the hydraulic audit cell. Within the audit cell the part is supplied with test fuel and tested in static and dynamic mode again.
These results are used as reference values to align the dry process to the wet conditions.
Before the robot finally offloads the injector the lower O-ring is mounted and the electrical pins of the terminal are checked by a camera.

 

GDI High Pressure Pump Performance Test Bench

The system is used to test cam driven high-pressure fuel pumps. The test bench simulates the mechanical drive and the low and high-pressure circuit.
The high-pressure pump is mounted manually on the CAM box and contacted by hand.
A change to other types of pumps is realized by changing the CAM-Box and the connection devices. The serial number of the pump can be read by a hand scanner.
There is also the possibility at the high-pressure output side of the pump to connect a customer specific rail, which is equipped with up to four injectors. These injectors can be controlled through the software or with a custom AUTO ECU. Measured signals are torque, current / voltage of the control valve, pressure and flow rates of the pump and injectors.
The inspection specifications are carried out by a database-flexible test plan system.
Individual test steps can be configured in any order and number and with different parameter settings to a flowchart. The results are recorded in a central database.

 

GDI Injector Flow and MOP

This test bench is used for the function testing of GDI-Injectors. Different injector types can be tested be means of adapters.
The bench is divided into two independent stations. In the flow station the injection quantity is tested by a Coriolis sensor and the injection timing is tested by a shotto-
shot system.
The spray station evaluates the injector spray. Not only ray, but also bottom view measurements are possible. The station allows manual tests and fully automatic test
sequences. All test parameters, like operating pressure, pulse width, injection frequency, can be set over the software.

 

GDI Injector Flow and Leak Test

This test rig provides the possibility to test the flow and leak values of a GDI-Injector. The rig has one central high-pressure supply and two separate stations.
The rig is realized with ATEX components and can be used with potentially explosive fluids.
A fast data acquisition allows to measure the current and voltage course on the injector.
An acceleration sensor can detect the opening and closing time of the injector.
The seat leakage measurement is done in wet condition.

 

Test Bench GDI-Injector

Bench for GDI injectors with 3 stations:

• Flow measurement
  Measurement of static and dynamic flow with a highprecision balance
• Spray test
  Optical measurement of spray geometry
• Liquid leak test
  Leakage measurement of closed injectors.

Realization as laboratory bench with high flexibility e.g. during product development processes.

 

Flow Test Bench Valve Seat

The flow test bench is used for verification of valve seats in GDI injectors.
The workpieces are manually loaded into the test station. The test bench offers high flexibility due to a simple change of the valve seat fixtures and a single changeover dialogue in the software.
The fully automated control software allows easy handling and high flexibility. Results and current values are displayed in the main window to guarantee an easy overview of the process.

 

“Dry Calibration“ of Gasoline Injectors

R&D bench for calibration and test of low pressure gasoline injectors in dry condition.
The obtained data and results are used for high-volume production process development.
In order to obtain detailed data sets, several measurement systems are combined with rapid data acquisition.
The recorded parameters and results are evaluated using the data analysis tool MATLAB.
The separation of data recording and analysis allows post processing of data with different settings and algorithms at any time.

 

Leakage Test for Gasoline Injectors

Test machine including five stations for measurement of valve seat leakage.
Automatic loading with conveyor interface to production line. High leakage injectors are classified and offloaded separately.

 

EOL Liquid Leak Test for GDI injectors

This test bench is an automatic system for the leak test of gasoline injectors.
The part handling takes the injectors from a conveyor belt and puts them in the nests of a rotary table. DMC-code of injector as well as RFID-code of the conveyor pallet are automatically transferred to a database. Now, the rotary table takes the parts to the run-in station and next to the
distribution axis.
The axis transports the test parts to the leak test stations. After the test, the injectors come back to the rotary table and the blow-out station. Finally, the parts get back to the pallet conveyor.

 

GDI injector flow and spray test bench

The test bench is designed for the entire analysis of important parameters of GDI-fuel injectors. Explosion protected components enable the operation with n-heptane as test fluid.
The bench provides the following test functions:

• Dynamic test in mg/inj (volumetric/gravimetric / shot-to-shot analysis)
• Static flow test in g/min (volumetric/gravimetric)
• Measurement of opening and closing times
• Injector spray characteristic (axial / radial spray geometry).

 

Spray and Flow Test Bench

The test bench is designed for the investigation of geometrical spray characteristics and for the static flow measurement of tow different Injector Sede types.
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 axial light sheet inspections. A motorized traversing system positions the axial light sheet optics.

 

Assembly and Final Test for GDI Injector Coils

This machine is used for preassembly and testing of coils for GDI injectors.
After the check by the operator the workpieces are inserted into workpiece carriers.
A conveyor belt is used to transport the parts to the preassembly stations where the o-rings and bodies are feeded by bowl feeders. The body and coil are fitted together with a press-in station.
The testing equipment has a rotary dial with an on- and offload station as well as additional testing stations. These are used for verifying different coil features. A laser marking station marks the coils with a Data Matrix Code.
It is possible to run mechanically two different coil types. A change-over is done automatically after selection by software. In addition, the workpiece carriers on the rotary table have to
be changed.

 

Final Check for Injector Coil

This machine is used for the final testing of coils for gasoline injectors.
After the check by the operator, the workpieces will be inserted into the workpiece carriers.
The test equipment has a rotary dial with an on- and offload station as well as additional testing stations.
These are used for verifying different coil features. A laser marking station marks the coils with a Data Matrix Code. It is possible to run mechanically two different coil types.
A change-over is done automatically after a selection by software. In addition, the workpiece carriers on the rotary table have to be changed.

 

Preassembly Injector Coil

This machine is used for preassembly and testing of coils for an gasoline injector.
The feeding of the body is performed by a bowl feeder. An numeric controlled axis takes the body from the unloading position and inserts the workpiece into the rotary dial.
A rotation station moves the body in a defined position. The next station is used for feeding the coil itself and inserts it into the body.
The next station is used to press-in the cover on the body. During the press-in process a force-stroke-diagram is recorded and evaluated.
An additional station is present to measure the resistance and inductance of the coil. A marker is marking OK parts. Finally, the parts are offloaded from the rotary dial into pallets
by means of an electrical axis. A pallet change over is done automatically.

 

Production Equipment for GDI Injectors

This production equipment is an automatic system for calibration and test of high-pressure solenoid fuel injectors.
The operation starts with loading the injector by means of a robot into a rotary dial. After reading the serial code (DMC), the injector enters the calibration unit. In the module the injectors are driven for about 150000 cycles in order to run-in and therefore stabilize the part.
The injector will be calibrated to a target flow, two additional flows can be rechecked at different test conditions. The next work process verifies the spray geometry of the injector by analyzing a shadowgraph taken image. Within the last performed work step the seat leakage will be tested with the patented liquid leak test.
Before unloading, the injector will be flushed out with air, so that the part will exit the production equipment in dry condition.
Finally, good parts will be placed into pallets, scraps will be sorted into the dedicated scrap rails.

GDI Sample Lab Equipment

Bench for GDI injectors with 2 independent stations:
Spray test: Optical measurement of spray geometry
Liquid leak test: Leakage measurement of closed injectors

Realization as laboratory bench with high flexibility e.g. during product development processes.

Calibration Line for GDI Injectors

This production line is an automatic system for calibration, test and final assembly of high-pressure solenoid fuel injectors.
It is a fully automatic line and able to perform the following process steps:

• Run-in with a functional check of the injector
• Calibration of the dynamic flow
• Measurement of static and dynamic flows with different driver parameters
• Measurement of spray geometry
• Liquid leak test
• Blow out
• Filter assembly
• Combustion seal assembly
• Optical connector-pin check
• Washer and snap-ring assembly.

The system is automatically loaded by a central robot combined with a conveyor system which connects the calibration modules. The line consists of several calibration modules with equal functionality and one assembly module. If one calibration module needs to be stopped (e.g. for
maintenance), the line will continue producing with less efficiency.

Calibration & test system for gasoline injectors

This production line is an automatic system for calibration, test
and final assembly of low-pressure fuel injectors. The machine is a fully automatic production line for performing the following process steps:

  • Check for damaged o-rings
  • Run-in with check of the solenoid by special driver cards
  • Static flow measurement
  • Calibration of the dynamic flow
  • Measurement of the dynamic flow
  • Blow out
  • Measurement of the tip-leak
  • Assembly of a top cap

The machine is automatically loaded by a robot. The injectors are placed into calibration fixtures and transported to the processing modules by means of a conveyor belt. The line comprises two calibration modules with the same functions. If one module needs
to be stopped (e.g. for maintenance), the line will continue producing with less efficiency.

Calibration and test line for Deka VII fuel injectors based on “Lean Concept”

This automatic production line with manual on- and offload is used for calibration, test and assembly of low pressure fuel injectors.
The following work steps are carried out:

  • regulated filter prepress to reduce cycle time
  • run-in of injectors with coil check supported by intelligent driver boards
  • static flow measurement
  • calibration of dynamic flow
  • dynamic flow measurement
  • seat leakage check with patented system
  • assembly of identification clip

μHammering Calibration Process

Conventional calibration processes with wedge adjustment or by spindle cannot meet the requirements of many applications with regard to higher positioning accuracy anymore. This results in an increased reject rate and rising production costs. Microhammering has been developed in order to meet these demands, to eliminate known disadvantages of the established technologies and to open up new possibilities in the field of assembly and calibration technology:

  • Significantly increased positioning accuracy
  • Elimination of the stick-slip effect during the press-in operation by micro-impuls feed rate
  • Reduced component stress by minimized static load
  • Intelligent process control with high robustness against batch influences and variations of the press fit tolerances
  • Reduced influence of the elastic component deformation on the positioning result

Microhammering obtains a feed rate, contrary to conventional processes, not with high static loads but with dosed force impulses in the microsecond range. This technology reduces the elastic deformation of the component as well as the consequent obstruction and increase of the press-in force. As a result, the components are exposed significantly lower effective forces and prevented from unsolicited material deformations.

More informations here...

GDI injector function test

The test bench has been designed for testing important characteristics of high-pressure piezo and solenoid injectors. It is equipped with explosion-proof components. The tests are performed with N-heptane.

The following test functions are available:

  • Dynamic flow tests (for determination of characteristic curves) in mg / inj depending on fuel pressure, injection frequency or drive pulse form.
  • Determination of opening and closing characteristics by laser vibrometer tests.
  • Determination of the injection process by shot to shot measurements.
  • Optical injection spray tests by radial and axial camera systems.
  • Injector seat leakage measurement by non-dispersive infrared (NDIR) technology

Calibration Line for GDI Injectors

This production line is an automatic system for calibration, test and final assembly of high-pressure solenoid fuel injectors.
It is a fully automatic line and able to perform the following  process steps:

    • Run-in with a functional check of the injector
    • Calibration of the dynamic flow
    • Measurement of static and dynamic flows with different  driver parameters
    • Measurement of spray geometry
    • Liquid leak test
    • Blow out
    • Filter assembly
    • Combustion seal assembly
    • Optical connector-pin check
    • Washer and snap-ring assembly

 

The system is automatically loaded by a central robot combined with a conveyor system which connects the calibration modules. The line consists of several calibration modules with equal functionality and one assembly module. If one calibration module needs to be stopped (e.g. for maintenance), the line will continue producing with less efficiency.

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

© conceptnet