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HE-Grinding Plant

The half automatic HE-grinding (hydro erosive grinding) module has been designed for flow calibration of high-pressure injection components to a defined target. Based on a rotary table concept the work pieces are processed in sequentially arranged stations of this module – HE-grinding, blow-off, purging, measurement. 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 camera.
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.

EDM-HEG-Modul

The full automatic EDM-HEG-Module is used for flow calibration of high pressure injection components. The complete module consists of a loader module with two EDM-Machines on the left and right side, and a HE-Grinder. The machine is filled with pallets loaded with nozzles utilizing a drawer system (6 drawers, 3 per each EDM system). The blanks are automatically removed of the pallets and loaded on the respective slide of the EDM system. Processed parts are removed from the slide and brought to the camera station to read the data matrix code. Afterwards, the nozzles are loaded into the rotary table of the HE-Grinder. There, the work pieces run through different processes in sequentially arranged stations: blow off E-water, pre-measurement, grinding, blow off grinding medium, flushing, final measurement, blow off test medium. The processed nozzles are loaded back on the pallet. Rejects parts are automatically sorted out. In addition, the machine can be loaded with nozzles of an alternative EDM-Machine, if the cycle time of the EDM-systems is larger than the cycle time of the HE-Grinder module.
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. All flow test results will be sent to the respective EDM machine for production quality optimization.

HE Grinding System for Diesel Nozzle Bodies

This production system calibrates the static flow of diesel fuel injection spray holes by using a special fluid grinding method. An abrasive liquid is pumped under high pressure through the injection spray holes. A specially designed and patented cylinder pump (Active Flow Meter method) generates a constant flow and supplies the nozzle with grinding fluid which passes the nozzle‘s spray holes. The spray holes, being initially too lean, generate an inlet pressure higher than the nominal pressure. Due to the abrasive fluid the inlet edges of the spray holes are being radiused and the inlet pressure decreases. The process is stopped as soon as the pressure measured upstream of the nozzle has reached the nominal value. The system design is modular and consists of max. three autarchic rotary tables being fed by a common loading system.

Abrasive flow machining

The automatic HE-grinding (hydro erosive grinding) module has been designed for flow calibration of high-pressure 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 1, purging, measurement, blow-off 2. 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 8-50% 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 automatically by a 3 axis-robot taking the workpieces out of the pallets and putting into the rotary table. For safe identification of the parts and for complete data traceability the dot code is detected on the workpieces by means of a camera. 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.

HE grinding station

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 nozzle has reached the nominal value. After the grinding process the work piece is cleaned with air. Using a high-viscous grinding oil (hydraulic oil with a maximum viscous range of 64) it is possible to machine work pieces with a specific output of up to 25 l/min. The module is designed as semitautomatic 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. The fixtures for the acceptance parts are included in the scope of supply.

Module for HE-grinding

This fully automatic HE-grinding module has been designed for radiusing the spray orifices of high pressure injection components to a defined target flow. Based on a rotary table concept the work pieces are processed in sequentially arranged stations of this module. After the HE-grinding the work piece passes purge and blowoff processes and is guided to the measurement station which is followed by the final blow-off process. By means of a pickand- place handling the work pieces are loaded and unloaded. During the grinding process an abrasive fluid is pumped through the orifices of the work piece with high pressure. The objective is to radius sharp edges and burrs by means of the HE-grinding method. The flow increase after this process is in average app. 10%. The grinding process is stopped as soon as the flow has reached the correlated target flow value. At the module 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.

HE grinding and flow test bench

The bench sets the static flow of nozzle bore holes or other injection components by means of a special fluid grinding method. An abrasive liquid is pumped under high pressure through the injector bore holes. A specially designed and patented cylinder pump (Active Flow Meter method) generates a constant flow and supplies the nozzle with grinding fluid which passes the nozzles spray holes. The work piece generates an inlet pressure higher than the nominal pressure. Due to the abrasive fluid, the inlet edges of the respective holes are being radiused and the inlet pressure decreases. The process is stopped when the pressure measured upstream of the nozzle has reached the nominal pressure. The work piece will be cleaned in a flushing station after the grinding process. Moreover, the test bench incorporates a measuring station which ascertains the static flow of the nozzle bores. By using adapters it is possible to process various work pieces. The process sequences of all stations which run independently from each other can be adapted to each type of work piece.

Fluid grinding plant for nozzles

This production plant 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 injector bore holes. A specially designed and patented cylinder pump (Active Flow Meter method) generates a constant flow and supplies the nozzle with grinding fluid which passes the nozzle‘s spray holes. The spray holes, being initially too lean, generate an inlet pressure higher than the nominal pressure. Due to the abrasive fluid the inlet edges of the spray holes are being radiused and the inlet pressure decreases. The process is stopped when the pressure measured upstream of the nozzle has reached the nominal pressure. The plant is modular and consists of max. three autarchic rotary tables being fed by a common loading system.

Manualy loaded fluid grinding bench

The bench sets the static flow of nozzle bore holes or other injection components by means of a special fluid grinding method. An abrasive liquid is pumped under high pressure through the injector bore holes. A specially designed and patented cylinder pump (Active Flow Meter method) generates a constant flow and supplies the nozzle with grinding fluid which passes the nozzle‘s spray holes. The work piece generates an inlet pressure higher than the nominal pressure. Due to the abrasive fluid, the inlet edges of the respective holes are being radiused and the inlet pressure decreases. The process is stopped, when the pressure measured upstream of the nozzle has reached the nominal pressure. The work piece will be cleaned in a flushing station after the grinding process. Moreover, the test bench incorporates a measuring station which ascertains the static flow of the nozzle bores. By using adapters it is possible to process various work pieces. The process sequences of all stations which run independently from each other can be adapted to each type of work piece.

Nozzle HE Grinding Machine

The automatic HE-grinding (hydro erosive grinding) module has been designed for flow calibration of high-pressure injection components to a defined flow target.
Based on a rotary table concept the work pieces are processed in sequentially arranged stations: HE-grinding 1 and HE-grinding 2 (different modes available), blow-off 1, purging, measurement, blow-off 2. 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 by 8 – 30% depending on the process. The grinding process is stopped as soon as the flow has reached the correlated target flow / target pressure value. The loading and offloading is done by a 3-axis-robot taking the work pieces out of the pallets and putting into the rotary table. For 100% data traceability the dot matrix code is detected on the work pieces by means of a camera.

 

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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