COMPONENTS: Combustion engine

display: none;

Gasoline and diesel injection pumpsendurance tests

Our component test benches for gasoline and diesel injection pumps enable the testing of defined test profiles for all common liquids, such as corrosive benzenes, worst-case diesel or fuels with high methanol or ethanol shares. In an endurance test controlling of the test objects is possible both with the original ECU from the vehicle as well as with the test bench electronics. Depending on the respective application, it is possible to perform parameter tests, such as leakage measurements or pressure holding tests, in the endurance test bench and thus to avoid downtimes and installation times. Furthermore our test benches offer the possibility to simulate real conditions with an additional fluid temperature conditioning. The tests are executed according to accredited in-house methods (PV 13, PV 14), for which 90 in-house produced test benches (80 gasoline and 10 diesel) are available. We are among the world market leaders in this test field thanks to our equipment as well as our many years of experience.

Performance indicators

  • Gasoline: up to 500 bar
  • Diesel: up to 3000 bar
  • Up to 130 °C fluid temperature
  • Variable feed pressure Up to 12,000 rpm
  • Methanol fuels, ethanol fuels Corrosive liquids
  • Up to 6 injectors/specimen
  • With and without original vehicle electronics

Gasoline and diesel injection system endurance test

Our endurance test benches allow system tests (pump injectors) for injection systems to be realized in addition to component tests. Controlling of pumps and injectors is, for example, possible with the original ECU from the vehicle or with the test bench electronics. Depending on the respective application, it is possible to perform parameter tests, such as leakage measurements or pressure holding tests, in the endurance test bench to avoid downtimes and installation times. Furthermore our test benches offer the possibility to simulate real conditions with an additional fluid temperature conditioning. The tests run according to the accredited in-house method (PV 13, PV 14), for which 90 own produced test benches (80 gasoline and 10 dieses) are available. We are among the world market leaders in this test field thanks to our equipment as well as our many years of experience.

Performance indicators

  • Gasoline: up to 500 bar
  • Diesel: up to 3000 bar
  • Up to 130 °C fluid temperature
  • Variable feed pressure
  • Up to 12,000 rpm
  • Methanol fuels, ethanol fuels
  • Corrosive liquids
  • Up to 6 injectors/specimen
  • With and without original vehicle electronics

Gasoline/diesel components service life endurance test in temperature change

Based on our standard endurance tests, our testing of diesel and gasoline pumps can be performed with or without injectors in endurance tests also under defined ambient temperatures. The physical challenges that result from the steam pressure of the fuel have to be controlled in this case.
Furthermore, we also offer operating the liquid temperature control against the ambient temperature which in turn means more complex challenges for the test bench.
By connecting e-machines we are able to realize highly dynamic test profiles parallel to the specimen temperature control.
Thanks to many years’ experience we are very familiar with challenges in this field so that we can realize manifold customer requirements at top quality.

Performance indicators

  • Up to 3000 bar
  • -70…130 °C fluid temperature
  • -70…180 °C ambient temperature
  • Variable feed pressure
  • Up to 12,000 rpm
  • Methanol fuels, ethanol fuels
  • Corrosive liquids
  • ATEX-compliant

Temperature change tests for hydraulic components

We are specialized in liquid temperature control with high temperature gradients across a wide temperature range. This means that we are able to use all common liquids in the automotive sector in our test facilities and create changed temperatures in the shortest possible time. Parallel to the liquid supply, specimens can also be operated hydraulically and/or electrically, if necessary in an explosion-proof atmosphere via nitrogen inerting.

Performance indicators

  • Test chamber volume: 2400 l
  • Temperature gradient: 24 K/min with nitrogen inerting
  • Dimensions: 2000 x 1000 x 1200 mm
  • Humidity: 5% – 98%

Injector lifecycle endurance test / Simulation combustion engine

In order to have realistic wear patterns at injectors we have developed test concepts which allow for a reproduction of the combustion engine temperature. It is also possible to heat the injector tip in such a way that the carbonization processes can be simulated in combination with oils and fuels.

Performance indicators

  • Vibration possible
  • Methanol fuels, ethanol fuels
  • Corrosive liquids
  • Pressure up to 500 bar
  • -40…180 °C ambient
  • -40…180 °C fluid temperature
  • Fluid temperature and ambient temperature can be controlled separately

Dirt contamination tests - pumps - injectors - complete system

A quite special but very important test case in the area of injection systems deals with fuel impurities and the interaction with the test object. Very small dust particles, such as standard dusts or original particles from the manufacturing of components, can be introduced in a defined manner into the liquid supply circuit of the specimen. The introduction of the particles can be controlled and measured online. Thanks to this possibility of calculated contamination, wear patters at specimens can be emulated or comparison tests be simulated. The required laboratory diagnostics of the liquids is part of our scope of services in the same way as the component analysis of the wear patterns.

Performance indicators

  • Dirt particles up to 100 µm
  • Online particle count
  • Up to 3000 bar
  • -40…130 °C fluid temperature
  • -70…180 °C ambient temperature
  • Variable feed pressure
  • Up to 12,000 rpm
  • Methanol fuels, ethanol fuels
  • Corrosive liquids
  • ATEX-compliant

Exhaust-gas after-treatment service life endurance test (SCR)

This endurance test offered by us puts our customers in a position to meet the latest emission standards. In the test the components are subjected to a service life endurance test with urea hydrous solution (UHS, AdBlue), whereby defined temperature profiles can be simulated and can optionally be tested with or without vibration.

Performance indicators

  • AdBlue liquid supply
  • Pressure up to 20 bar
  • Temperatures up to 180 °C

Pulse start coupling tests up to 95,000 rpm/s

Due to new vehicle architectures the requirements for components in the drive train and at the combustion engine are in part changing in extreme ways – example: Hybrid vehicle. Due to the exceptionally high dynamics when the combustion engine is started, the fuel pump is also confronted with new demands. Speed gradients of up to 95.000 rpm/s and the pressure build-up that comes with this during the start process have to be simulated at the test bench. With constantly improving, state-of-the-art systems we meet these requirements and are able to fulfill the high demands of our customers.

Performance indicators

  • Up to 3000 bar
  • 120 °C fluid temperature
  • Variable feed pressure
  • Up to 95,000 rpm/s

Endurance testing of thermal management and hydraulic component tests

Our endurance test benches allow the combined exposure to different ambient and liquid temperatures during operation with the specimen. In the process highly viscous liquids can be used with low temperatures (up to -40 °C). Controlling of the specimen is, for example, possible with the original ECU from the vehicle to simulate a stress as realistic as possible. Depending on the respective application, parameter tests, for example leakage measurements, can be passed through in the endurance test bench. The goal is the elimination of downtimes and installation times. The compact design of our self constructed test benches enables parallel testing of several specimens in one test bench. Every test bench is characterized by high flow rates under steep temperature gradients, resulting in the time compression of the respective tests. Thanks to these technical possibilities we are able to test a wide range of products on our test benches.

Performance indicators

  • Up to 250 l/min
  • -40…130 °C fluid temperature
  • -70…180 °C ambient temperature
  • Variable pressure
  • Oil up to -40 °C
  • 12,000 mPaxs

Key Figures:

Matthias Benkert

Engineer mechatronics
Division: Injection systems
Phone: +49 9524 2961-214
E-mail: matthias.benkert@pid-gmbh.de

PID - test & engineering GmbH · Obere Länge 26 · D-97522 Sand am Main · Tel.: +49 9524 2961-0 · E-Mail: info@pid-gmbh.de