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Manual loaded HEG

The half automatic HE-grinding (hydro erosive grinding) module has been designed for flow calibration of diesel injection components to a defined target. Based on a rotary table concept the work pieces are processed in sequentially arranged stations of this module – pre measurement, HE-grinding, blow-off, purging, measurement, blow-off. During the grinding process an abrasive fluid is pumped through the orifices of the workpieces in order to radius bore hole intersections. The flow will be increased by
8 – 30 % depending on the process. The grinding process is stopped as soon as the flow has reached the correlated target flow value. The loading and unloading of the module takes place manually. For safe identification of the parts and for complete data traceability the dot code is detected on the workpieces by means of a scanner.
A moveable control panel with a comfortable user interface is installed. Running processes and results are displayed.
The parameters can be easily adjusted in case of changing requirements.
The retrofit of a loader module for the loading of a HE grinding machine and a EDM machine is given. The loading and unloading is done by a 6-axis robot. The dot code reader is integrated in the loader module.

 

Single Head HE Grinding Machine

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 work piece has reached the nominal value. After the grinding process the work piece is cleaned with air.
The module is designed as semiautomatic 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.

 

 

 

 

HE-Grinding of Orifice Plates and Nozzle Bodies

The machine is used for processing and testing of orifice plates and nozzle bodies. There are three manually loaded stations (measuring station, flushing station and grinding station). 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 and purged in the flushing station. The final flow control of the machined work piece takes places in the measuring station.

HE Grinding Machine

The semi-automatic hydro erosive grinding module has been designed for flow calibration of injector components to a defined target. Based on a rotary table concept the work pieces are processed in sequentially arranged stations of this module:

 -grinding inlet
 -flushing inlet
 -measure inlet
 -grinding outlet
 -flushing outlet
 -measure outlet

During the grinding process an abrasive fluid is pumped
through the orifices of the work pieces in order to radius bore hole intersections. The flow will be increased and stopped as soon as the flow has reached the correlated target flow value.
A moveable control panel with a comfortable user interface is installed. Running processes and results are displayed. The parameters can be easily adjusted in case of changing requirements.

 

Hydroerosive grinding plant

The plant serves to set the flow through orifices of diesel injection components. The plant comprises two grinding modules and one measuring module. One grinding module comprises four simultaneously working stations which are supplied with parts by a servo motor linear axis with four grippers. After the grinding operation the parts are cleaned in the integrated cleaning station and placed on the work piece carrier for transport to the next module. The measuring module comprises six stations which measure two orifices within each work piece . The parts are supplied analogue to the grinding modules. Parts that fulfil the test plan demands are provided with a dot code in the last working step which is performed by means of a laser. The modules are linked by an automatic conveyor belt system where work piece carriers are transported. The work piece carriers are loaded and off loaded by a robot loading station.

Abrasive flow machining system

The system has been designed for calibration of orifices of diesel injection components to a defined target flow. The system comprises several modules. A robot cell that loads and unloads the workpieces onto/off the pallets. A conveyor system connecting up to 11 HE grinding (hydro erosive grinding) modules that machine, flush and flow test the parts. There is one combined module where an audit station, a laser marking station and a re-reading station are integrated. A robot cell consists of a robot and two loading and unloading stations. The machining modules comprise 7 stations (2 HE-grinding stations, 2 flushing stations, 2 flow test stations and 1 blow-off station).
The grinding stations round the sharp edges of the bore hole intersections and calibrate the flow to a target flow. In the following flushing stations any remaining grinding fluid and other contamination is cleaned off the workpiece. Afterwards, the actual flow is checked in the flow test stations. Parts within the determined tolerances are put into the workpiece pallet or otherwise into a scrap part box. The audit station checks a certain part of production. By means of the measurement results the flow test stations of the HE-grinding modules are adjusted. In case of high deviations, the respective module will be stopped and mastered.
Finally, the laser marks a dot code onto the workpiece. The following re-reading station checks the legibility of the code. 

HE-Grinding of Injector Orifice Components

The automatic HE(= hydro erosive)-Grinding module is used for flow calibration of two orifices within each work piece. The machine is based on a rotary table concept: 2 x grinding station, 2 x washing station, 2 x measuring station and 1 x blow out station

HE-Grinding
The HE-Grinding process calibrates the static flow of diesel fuel injector bore holes by using a special fluid grinding method. An abrasive liquid is pumped under high pressure through the respective bore hole intersections. A specially designed and patented cylinder pump (Active Flow Meter method) generates a constant flow and supplies the work piece with grinding fluid. The bore hole intersections, being initially too lean, generate an inlet pressure higher than the nominal pressure. Due to the abrasive fluid the edges of the intersections are being radiused and the inlet pressure decreases. The process is stopped when the pressure measured upstream has reached the nominal pressure. It is also possible to generate constant pressure and to stop the process after having reached a defined target flow. Variable flow increase is possible.

Washing
After HE-Grinding the work pieces are cleaned from residues of grinding media.

Flow test
To verify the correlation between HE-grinding process and flow test with General view ISO 4113 fluid.

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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