Our Processes

The hydraulic flow test determines the volumetric and mass flow rate of a component.
For this purpose, measuring fluid is passed through the said component under defined parameters (pressure, temperature), while a sensor records the flow.

During the air leak test, the airtightness of components is tested by means of pressure drop, pressure rise or differential pressure. In the process, the test item is impinged with compressed air or a vacuum. Based on the request of the client, external or fully integrated Sonplas systems (software and mechanical system) may be used for the test.

The pneumatic flow test is a process during which thermodynamic transformations occurring while gases are passed through components are measured.
Using a Coriolis flow meter, the air mass flow rate is measured, or alternatively, the air volumetric flow rate is measured by using laminar nozzles or filaments (heating wires). External or fully integrated Sonplas systems (software and mechanical system) may be used for the test.
Due to the high measurement accuracy, precise conclusions can be made about the respective characteristics with even the tiniest components at very low fluid pressures.

For the hydraulic leak test (watertightness test), the test item (generally an injector valve) is impinged with an operating fluid (e.g. fuel, Exxsol). As part of the automatic test sequence, a measuring chamber is mated to the valve seat of the test item which detects and measures the smallest quantities of leakage flow. Due to the system’s high measurement resolution, even leaks of < 1µl/min can be detected and measured. Fluid conducting circuits are used in many sectors of the industry. Hydraulic circuits in industrial systems and components of fuel carrying systems in combustion engines are only two examples.
The airtightness of the system is the main factor for the effectiveness and environmental compatibility of these circuits. Both leaks within the circuit (leaking valves) and leaks to the outside must be identified and eliminated to the maximum possible extent.
This is why checking the airtightness (leak test) both during production and in the lab is especially significant. The hydraulic leak test (watertightness test), for example, constiutes a well established method.

The helium leak test (He leak test) is an extremely precise measurement procedure for the airtightness of components (up to 1.0E-08mbar*l/sec leak threshold). Both integral measurements within the vacuum chamber as well as local measurements taken by means of sampling (sniffer) probes may be used. This process can be integrated in small manual workstations as well as in series production systems.

During the spray test by a vision control system, emitted beams, mainly from injection components, undergo a geometric analysis. For this purpose, all kinds of angles (beam angle, elevation angle, intermediate beam angle) are measured and evaluated using the Sonplas vision software. In addition, cylindrical beams/rays may undergo a cylindricity evaluation.

During the opening pressure test, the maximum pressure before the nozzle needle is lifted from the nozzle seat is established. This test serves indirectly to determine the hydraulic effective area of the nozzle assembly that cannot be established with conventional measurement of dimensions. The test requires quick recording of the pressure to be able to analyse the highly dynamic opening process of the nozzle with a high resolution.

The nozzle geometry test serves to assess the results gained from hydro-erosive deburring/chamfering or flow calibration.
This geometric analysis is carried out by means of a bore scope, or by producing a negative image of the nozzle which is subsequently examined under the microscope.
In the process, different characteristics of the nozzle (conicity, rounding, erosion, etc.) are checked and evaluated.

During the hydro-erosive processing, an abrasive fluid is pumped under high pressure through the workpiece boreholes to deburr and round edges. By improving the quality of the surfaces, the high pressure resistance of the workpiece is enhanced at the same time.

During the hydro-erosive processing, an abrasive fluid is pumped under high pressure through the workpiece boreholes to deburr and round edges. By improving the quality of the surfaces, the high pressure resistance of the workpiece is enhanced at the same time.

Using the Micro-hammer is a high-precision press-in process. Advantages compared to conventional press-in procedures include a higher positioning accuracy and the option to press in very small increments. Therefore, components that are already very close to the target can still be further processed as the stick slip effect does not occur when using micro-hammers. This allows to work with increments that are smaller than 1 µm.

For the calibration of the flow rate, an abrasive fluid is pumped through the boreholes of a component under defined pressure, rounding off the inlet edges while optimising the flow rate.
During the milling process, the increase of the flow rate is continually monitored by a sensor, allowing adjustment of the target flow rate specified by the client with extremely high precision.

With the injection measuring system, the blasting rate performance of diesel and fuel injectors is established based on the operating parameters. In doing so, injection masses can be measured with high precision, and differentiated conclusions can be made regarding the time sensitive volumetric efficiency during an individual injection.

Pressure relief valves integrated in fuel pumps, for example, to protect all assemblies connected within the fuel circuit against excessive pressures, are adjusted during the calibration of the opening pressure.
A narrow tolerance range is crucial for an efficient design of the component and its service life. Therefore, this characteristic feature is of significant importance.
During the calibration, the closing pressure of the valve and thus the opening pressure is set by compressing a spring. High precision during the press-in process and exact determination of the opening pressure are crucial factors for an accurate calibration. Direct and indirect measuring procedures based on the composition of the client’s component are available for this matter.

Capacitor discharge welding (CD welding) refers to a resistance welding process with extremely quick welding times (<10ms) and very high degree of efficiency (approx. 90%). Almost all the energy is applied to the welding point (stud) ensuring that the component experiences a minor warm up only. Sonplas has developed a device concept that can be easily financially integrated in the production lines.

During the laser inscription, the component surface is altered by a laser beam (as opposed to a substance being applied to the surface for an imprint or labelling with ink, for example). This makes the label or marking more durable, while ensuring better traceability throughout the entire service life of the product. This procedure can be applied to almost all conventional materials.

Cleaning refers to the workpieces being cleaned after the hydro-erosive processing. The workpieces are purged and cleaned in accordance with the SAE norms.

Laser welding is a welding process with very high speeds, relatively narrow seams and low energy input. The monitoring of the laser welding process can be carried out in advance (e.g. optical seam tracking), in retardation (e.g. optical or sensory seam control) or in parallel in real time (e.g. back reflex sensors for process light evaluation, light sensors). The process can be integrated into both manual workstations and fully automatic machines.

 

If a risk of explosion is posed due to substances in the machinery or processes carried out with the machinery, appropriate protective measures in compliance with the ATEX Directive are implemented based on an ignition source analysis.

Nowadays, noise emissions have developed into a quality criteria for state-of-the-art, high quality vehicle pumps. Structure-borne noise emission is measured by means of standard measuring methods and procedures supported by laser vibrometers.

The press-in process is a permanent bonding technique. Depending on the requirements, we can fall back on diverse systems for this purpose: e.g. Hand lever presses, servo spindle axes, servo-pneumatic and servo-hydraulic systems, piezo systems, electrical direct drives. For the monitoring, control and regulation, external devices or fully integrated Sonplas systems (software or mechanical system) are used.

Using the Micro-hammer is a high-precision press-in process. Advantages compared to conventional press-in procedures include a higher positioning accuracy and the option to press in minor increments. Therefore, components that are already very close to the target can still be processed further as the stick slip effect does not occur when using micro-hammers. This allows to work with increments that are smaller than 1 µm.

Wolfram inert gas welding refers to an arc welding procedure under inert gas. For the series production of electronic components, Sonplas has developed a burner head with automatic adjustment of the electrode, and a quick change system for the reproducible exchange of electrode and nozzles.