Universal Test Device for Injection Components
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Solution Overview
Problem
The need for multiple devices to test different types of injection components in a motor vehicle workshop leads to increased costs and space requirements, as existing systems are not versatile enough to measure various characteristics of nozzle holder combinations and injectors effectively.
Innovation Solution
A single test device that utilizes a pressure generation unit to simulate the operation of different injection components, including nozzle holder combinations and injectors, by controlling a common rail high-pressure pump to measure opening pressures and flow rates, allowing for the evaluation of various injection components with the same system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate test devices are used to test different types of injection components (injectors and nozzle holder combinations), then the measurement precision and reliability for each component type is ensured, but the device complexity, costs, and space requirements increase significantly
Solution Approach 1:
The test device is designed with a universal pressure generation unit that can simulate different operating modes (injector operation and nozzle holder combination operation) using the same hardware. The control unit enables the single pressure generation unit to adapt its behavior through software control, allowing one device to perform functions that previously required separate specialized devices for injectors and nozzle holder combinations
Solution Approach 2:
The invention changes the operational parameters and control characteristics of the pressure generation unit to simulate different component behaviors. By adjusting control parameters such as pressure buildup rate, pressure profile shape, and activation timing, the same physical device can replicate the distinct operational characteristics of injectors versus nozzle holder combinations, eliminating the need for physically different devices
2Measurement precision
If separate test systems are used for injectors and nozzle holder combinations, then each component can be tested with optimized parameters, but the space requirements and costs increase
Solution Approach 1:
A single test device incorporates multiple testing capabilities for both injectors and nozzle holder combinations within one workspace. The universal pressure generation unit and control system enable the same physical space to accommodate and test different injection components sequentially, reducing the total area required compared to having separate dedicated devices for each component type
3Ease of manufacture
If a pressure generation unit is designed specifically for injectors, then injector testing is optimized, but it cannot test nozzle holder combinations without physical modification
Solution Approach 1:
Instead of physically modifying the pressure generation unit, the invention uses software-based parameter changes in the control unit to adapt the device's behavior. The control unit modifies operational parameters such as pressure buildup characteristics, activation patterns, and timing to match the specific testing requirements of nozzle holder combinations, maintaining hardware simplicity while achieving versatility
Solution Approach 2:
The pressure generation unit is designed with inherent versatility, capable of operating in multiple modes (injector simulation and nozzle holder combination simulation) without physical changes. The control unit enables the same hardware to adapt its functional characteristics, allowing a single unit to serve multiple component types and testing purposes
4Adaptability or versatility
If electrical control is used for the pressure generation unit, then different behaviors can be simulated without physical changes, but the control complexity increases
Solution Approach 1:
The control unit manages complexity by parameterizing different operating modes through software rather than hardware complexity. Different pressure profiles, activation patterns, and timing characteristics are achieved by adjusting control parameters and stored program data, keeping the physical hardware simple while enabling versatile operational behaviors through electrical control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the measurement of first and second opening pressures of nozzle holder combinations and the pressure characteristics of injectors with a single device, reducing the need for multiple systems and improving efficiency by simulating different operating states of injection components without physical changes to the pressure generation unit.
Implementation Method 1
a pressure generation unit which is used in a first operating mode to check injectors and therefore builds up a pressure profile over time which corresponds to the normal operation of injectors
Implementation Method 2
the pressure generation unit being activated in the second operating mode in order to simulate the pressure profile of an in-line pump
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to a test device for checking injection components, comprising a control unit, a pressure generating unit (10, 110, 210) selected by the control unit (50, 150, 25), and a test specimen holding unit (40, 140, 240, 340), which is equipped for connecting a test specimen and connected to the pressure generating unit, wherein the controller selects the pressure generating unit such that the pressure generating unit on the test specimen holding unit provides different, selectable pressure curves for the test specimen that can be connected. The invention further relates to a method for checking injection components, comprising the following steps: generating a first pressure curve by means of a pressure generating unit; adjusting the pressure generating unit to a second pressure curve, which differs from the first pressure curve; and generating a second pressure curve by means of the pressure generating unit, wherein the adjusting of the pressure generating unit comprises the adjusting of a selection of the pressure generating unit without performing physical adjustments on the pressure generating unit.