From e-fuels to diesel
Sonplas brings extensive expertise in testing fuel-contact components for all types of media.
For fuel technology, Sonplas produces both assembly systems and test benches for components that interact with fuels.
The specialized machine manufacturer is focused not only on future-oriented technologies like hydrogen, e-fuels, and
methanol, but also on traditional gasoline and diesel.
This ensures that the mechanical engineering company continues to support its customers in sectors like automotive,
off-highway, large engines, and aviation, maintaining long-term business relationships without leaving anyone behind.
You will continue to receive comprehensive advice and solutions from a single source.
“Even though the topic of e-mobility has been pushed to the extreme in the
automotive industry in recent years, fuels such as gasoline or diesel are by no
means out of the picture,” Lukas Sepaintner is convinced. After all, the industry
must retain the ability to choose which future mobility solutions to invest in.
Sepaintner is a sales engineer at Sonplas. The mid-sized specialized machine manufacturer based in Straubing, Bavaria, now has nearly 30 years of experience
in assembly and primarily in testing fuel-contact components in injection systems,
such as valves, injectors, pressure regulators, fuel rails, injection pumps, and pre-
feed pumps. As a service provider, Sonplas also offers the option to test the functionality and service life of hydrogen-carrying components on its own test
bench, for example. The specialized machine manufacturer has its own in-house
fuel laboratory for this purpose. Feasibility studies and product tests further
enhance the range of services available to customers.
Typical processes include testing the flow rate, leak tightness, spray pattern, measuring opening and closing times, determining the injection rate, and testing the temperature. Both functional and endurance tests of individual components and complete systems
are possible.
The customers primarily include suppliers from the automotive, off-highway, large engine, and aviation sectors. “We design our test benches on a modular basis and can customize them precisely to meet the customer’s requirements,” explains the Sonplas engineer. “What sets us apart from our competitors is our ability to work with a wide range of media used in mobility, including gasoline, diesel, hydrogen, ammonia, e-fuels, methane, LPG, CNG, methanol, kerosene, water, and even ethanol,” explains the Sonplas engineer.
left: Gasoline injector
center: spray pattem test
right: spray test
Since the test devices for the various fuels do not differ significantly, the specialized machine manufacturer has consolidated its expertise in fuel injection systems and
offers customers a complete range of solutions from a single source. The experts at Sonplas are able to design various test benches based on the medium, including fuels
that are subject to legal requirements for explosion protection. Sonplas uses actual
fuels to ensure testing is conducted under real-world conditions. What matters is
not just the expertise during execution, but also the guidance provided beforehand
and the support during acceptance. This includes helping the customer integrate
their test bench into their facility.
left: Pump test bench
center: Gasoline model
right: Automated injector assembly system
Sonplas offers support not only in developing complete test benches but also in optimizing existing systems. The experts focus on minimizing the cost of conversion measures. Thanks to the modular design, Sonplas can expand and retrofit devices
as needed, such as when environmental conditions change. Units can also be omitted
if they are not necessary. “This results in significant cost savings for the customer,”
says Sepaintner.
On board right from the start
Sonplas is not only a dependable partner for testing components but also for developing the systems and components themselves. “By getting involved early in the process, our technicians find the most efficient solutions during product development,” assures Sepaintner. Their requirements vary, for example, in terms of material compatibility, seal selection,
or the size of the holes through which the cables are routed.
Sonplas offers both assembly and testing from a single source, efficiently integrating both disciplines into its solutions.
With a proven network of carefully selected and reliable partners, users receive a comprehensive package and have only
one point of contact. This streamlines communication, reduces organizational effort, and minimizes interface issues. “We
know precisely what matters when it comes to components,” says sales engineer Sepaintner with conviction. “This ensures
we are always on the same level as our customers, which is a significant added value.”
For injectors in combustion engines and for all other media such as hydrogen, ammonia, e-fuels, methane, LPG, CNG, methanol, kerosene, water, or ethanol,
Sonplas offers a solution with the IAV Cross – Injection Analyzer. This device
measures the injection rate by detecting the dynamic pressure increase in a
fuel-filled measurement channel. It can measure both injection rates and
quantities individually and simultaneously and display the rate signal with
high precision. Since the system has no moving parts, it requires minimal
maintenance and provides consistent, reproducible results. The measuring
unit is controlled by advanced software that is user-friendly and provides a
clear, real-time display of all relevant information. Users can also connect
the IAV Cross – Injection Analyzer by Sonplas to their test bench software
via a software interface, seamlessly integrating it into their digital test and
development environment.
