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High pressure common rail diesel fuel pump bench

This machine was designed and built to perform a full functional test on an electronic common rail diesel fuel pump. The bench completely maps the pump characteristics as well as the individual pumping elements across the complete operational range.

• Generates performance map for assembly and elements
• Integral crane assists with loading/unloading
• Interlocked safety cover slides into machine for access to parts.

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Diesel Common Rail Fuel System

This machine was designed to test a complete Diesel common rail fuel system, which consists of the pump, rail and injectors. Each injector was instrumented for bypass flow, bypass pressure and bypass temperature while also measuring the individual injector discharge to the split level up to 5 splits. The common rail pump was driven with a variable speed drive and was instrumented for pressure, flow, bypass flow and temperature. Ideal for lab use, this machine could completely map the characteristics of a common rail diesel fuel system as well as endurance test and audit test the product.

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Various Diesel fuel Injector endurance machines

Most of these machines endurance test several diesel fuel injectors at a time, at normal operating pressures and rates. They are intended to run for extended periods of time unattended.

Some of these designs utilize the engine head or block, while others utilize custom fixturing. Other endurance type machines include steering gear shaft seal endurance for linear and rotational motion.

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Typical EUI style fuel injector functional test machine

This machine is typical of our manual loaded style EUI or MUI fuel injector test machine. These machines are for production use and measure discharge volume, injection timing, peak injection pressure and body leakage.

• Interchangeable fixturing to accommodate 5 of customers products
• Hood opens for easy fixture access for maintenance
• Proven design provides years of painless service

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Fuel tank vapor tube assembly and test

This machine assembles a vapor tube subassembly by inserting a fitting onto a flexible tube and then plugs the end to perform a leak test. The machine is manually loaded by an operator and assembles two subassemblies in 10 seconds.

• Verifies fitting insertion with laser
• Measures very low flow rates
• Passed parts are marked to verify 100% test
• Failed parts must pass through reject chute for guaranteed containment of non-conforming product.

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Direct Gasoline Injection pressure control valve functional test

This machine performs a production end of line test on a direct injection gasoline system pressure control valve. Features such as valve opening response, valve closing response, proof pressure and other pressure control characteristics are being measured.

The machine automatically engages the part, performs the test and logs the data locally and to a server.

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HEUI Style Diesel Fuel Injector Bench

This machine is typical of our manual loaded style HEUI fuel injector test machine. These machines are for production use and measure discharge volume, injection reaction time, and seat leakage. Some machines are designed to accommodate top and body fed HEUI products.

• Machine controls peak oil rail pressures up to 32 MPa
• Fixture and rail configurations can accommodate a variety of HEUI injector types
• Reservoir is temperature controlled
• Utilizes PFIM technology to fire injectors
• Measures discharge, timing, upper and lower seat leak

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Injector Assembly and Test Cel

This particular machine was designed to assemble and test a complete diesel fuel injector all in a self-contained package with a small footprint. A single operator loads pallets with the individual components that make up the injector. As the pallet passes through the machine, the injector is incrementally assembled and tested for different characteristics and marked for identification. The design is flexible to accommodate future product design and increased product throughput. The entire package is also easy to move in a short period of time.

• Accommodates several injector products with minimal changeover.
• Pallets are tracked with RF tags meaning that pallet order is unimportant and can be random.
• Each test station pulls out on slides so that the hydraulics can be easily serviced.
• Machine logs all test results to local hard drive.
• Machine vision verifies stamping on body against currently selected part parameters.
• Designed for one man operation.
• Functional test station performs mass flow, VOP, guide leak and tip leak tests selectively and in any order.
• Assembly station uses a multi axis robot to select shims from forty different magazines.
• These magazines can be loaded in any position, as the machine will learn what shim thickness has been installed. This robot also installs the cap in a nut runner.
• Assembly station uses an encoder to measure every shim prior to installation to guarantee that the correct shim was installed.
• Sensors detect the presence of an o-ring that should have been installed on the part.
• Each station can be manually operated for debugging.
• Pallets can be routed to one station only, all of them or any combination. This is useful for running masters or marking parts.
• One hydraulic power unit provides temperature conditioned calibration fluid to all of the stations.
• All filters have two stage differential pressure switches to provide an early warning of filter failure.
• Automatic plant fill circuit refills the calibration fluid tank from a plant feed, when the tank becomes low.
• Spare station slots can accommodate redundant stations for faster throughput or different stations so that products can be intermixed in the future.

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Fuel Injector Nozzle test machine

This machine is one flavor of many injector nozzle machines that we make.

This one in particular is two machines in one, capable of running two completely different products at the same time with one operator. This machine is capable of flowing a 14 kg/Min fuel nozzle at 55MPa for an indefinite length of time! During this time we maintain pressure at the nozzle inlet within 3 kPa! The machine also performs a VOP (Valve opening pressure) test, leak down test, tip leak test and Buzz test. The buzz test actuates the nozzle group at 2-10 Hz and makes several VOP measurements to report an average and sigma. The entire test cycle takes 30 seconds.

• Nozzle testing weeds out bad nozzle before they are incorporated into the fuel injector and saves costly tear down and rebuilds.
• Fast test cycle allows machine to outpace injector testing, leaving room for testing other products.
• Universal fixturing allows fast changeover between several different product types.
• Self-extracting fixturing makes part insertion and removal a breeze for the operator.
• Two headed versions can be built with separate tanks so that different fluids may be used on each side.

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Liquid Lead Measurement/Injector Barrel and Plunger Assembly

This machine performs a precision assembly of a fuel injector barrel and plunger and then performs a gauging operation to verify that a dimension is correct. A robot is used to perform the material handling operations and a conveyor system allows several trays of parts to be queued up for unattended operation. The gauging measurement uses signature analysis to perform the measurement.

• Completely self contained in small footprint
• Fixturing can be changed over to accommodate other parts.
• Robot populates dedicated "reject" tray
• One operator can attend several machines

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Pro One EUI

The full-featured, flexible and portable Pro One EUI lets you expertly test a full range of solenoid-based EUI diesel injectors.

This is one of the few standard machines in our stable

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