Leak Testing Fuel Injector Components

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A vehicle’s fuel injection system is responsible for injecting fuel into the engine cylinders, where the gas is burned to produce engine power. A leaky fuel injector, which is a common fuel injection system problem, can significantly compromise engine performance and produce a variety of symptoms.

As described in this article on eHow.com, small things like an erratic engine idle, a misfiring engine, reduced gas mileage and worst case, an excessive fuel leak onto the hot surfaces of the engine intake manifold or engine block causing the fuel to ignite and cause an engine fire. These problems can be arrested in the first instance with accredited testing systems.

Faulty fuel injector components not only are a threat to the end-user / consumer’s life, they also make terrible testimonials to your quality control. That we know isn’t the ideal situation for a component manufacturer, be it of any size.

InterTech’s leak testing solutions offer you unsurpassed excellence in testing solutions, both leak and functional. Here’s one such solution that has helped many manufacturers of fuel injector components to test and verify leaks in their manufactured components.

The Challenge

Fuel injection components often demand 100% leak testing to limits as low as .01 sccm with cycles as fast as 2.5 seconds, 10% R&R quality requirements, while also displaying significant part temperature variations.

Separate tests with different limits are typically needed in the same test cycle for body welds, seat leakage, and overall leakage. Integration of instrumentation software, fixturing and test circuit is essential, as is complete test documentation.

DR-109-Fuel-Injector-Components

Fuel Injector Test Fixture and Parts

Test Process and Solutions

InterTech’s downstream test process features a patented Micro-Flow mass-flow transducer to provide 10 times greater leak sensitivity than any other dry-air test method. A test part is enclosed within a test chamber and pressurized; leakage is measured as a flow increase into the test circuit outside the part, eliminating the need and time for pressure stabilization inside the part. The test circuit is precisely engineered for minimum volume, enabling the Micro-Flow sensor to almost instantaneously measure flows with a resolution of .0001 sccm.

Critical for fast small-leak testing, all fixtures and clamping devices are designed and built for absolute stability to prevent part movement during testing. Seal positioning mechanisms consistently address the test part squarely and firmly, stabilizing their closure forces quickly to shorten cycle times.

Seals are designed for high durability to run thousands of parts per day without replacement. With these unique features, Micro-Flow dry-air test systems deliver .01 sccm testing with less than 10% R&R.

Special Features

  • InterTech’s Patented Bias-Leak checking is especially important for fail-safe operation whenever testing to less than 1 sccm. It uses low-level airflow to confirm test-circuit integrity before each test cycle.
  • Temperature compensation sharpens test accuracy and repeatability by nullifying test part residual heat from welding, fabrication, washing or even operator handling. Custom algorithms based on the test part’s unique cooling characteristics supply appropriate corrective responses across the test cycle.
  • InterTech’s S-3085 networking/diagnostic software graphically visualizes for greater operator control the factors that can compromise a good baseline zero, trigger false rejects or otherwise disrupt accuracy and repeatability.

Follow the InterTech India blog for more solutions on leak and functional testing. For sales enquiries, you may contact us at;

Mobile: +91 994 032 0718

eMail: ajay@intertechdevelopment.com

Land phone: +91 44 4211 2525

 

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