Last Man Standing
Sonplas continues to focus on gasoline and diesel fuels with its assembly and testing systems.
While many competitors have long since moved away from combustion technology, Sonplas continues to drive
innovation in the fuel sector alongside pioneering new technologies. The special-purpose machine manufacturer
develops highly specialized assembly systems and test benches for components that come into contact with gasoline
and diesel—and it will continue to consistently pursue solutions for conventional combustion technology in the future.
This positions the company as the “last man standing” in a rapidly evolving market. With this clear commitment, Sonplas
provides customized, turnkey solutions from a single source for customers in Europe, the United States, and China.
Last Man Standing
Shifting from combustion engines to e-mobility? “Today, the market is focusing equally on both technologies,” says Lukas Sepaintner, Sales Engineer at Sonplas. The medium-sized special-purpose machine manufacturer based in Straubing, Bavaria, now has nearly 30 years of experience in assembly, but primarily in testing fuel-contact com-
ponents in injection systems, such as valves, injectors, pressure regulators, fuel rails, injection pumps, and pre-feed pumps.
For a long time, battery electric vehicles seemed to be the only way forward. Auto-
makers increasingly aligned their model ranges and drive technology with electric vehicles. While this technology remains important, interest in solutions for combustion engines is now clearly on the rise again. “The US and, above all, the Chinese markets are particularly interesting. The Chinese government is actively promoting the further development of combustion technology,” emphasizes Sepaintner. In these regions, automation is becoming increasingly important in the testing and assembly of components. Several Sonplas systems are already in operation, and interest in automated assembly and testing solutions continues to grow.
“For example, we can not only assemble a gasoline pump, but also test it with the appropriate medium,” explains Sepaintner. “That is a clear unique selling point.”
The special-purpose machine manufacturer operates its own in-house test laboratory to support the development of test benches and to assist customers with prototype testing. Feasibility studies and product testing further expand the range of services available to customers. Typical processes include testing flow rate, leak tightness, and spray pattern, measuring opening and closing times, as well as determining the injection rate. Both functional and endurance tests can be performed, either on individual components or on the entire system.
Sonplas continues to provide pump test benches for traditional diesel (left) and gasoline models.
The experts design the test benches using a modular approach and tailor them precisely to the customer’s requirements. This enables Sonplas to expand or retrofit the systems at any time, for example, in the event of changed environmental conditions. Unnecessary units can be omitted, and all legal requirements for explosion protection are fully met.
Sonplas can perform safe testing of components using both real fuels and specialized test media. “What matters is not only the technical expertise during implementation,
but also the upfront consulting and support during final acceptance,” says the Sonplas engineer. “For instance, the customer needs to be able to integrate the test bench into their facility.” Development in combustion engine technology continues to move forward. To make engines more efficient while at the same time reducing emissions, fuels need to be atomized more precisely within the combustion chamber. “At present, injection pressure in gasoline injectors is around 500 bar,” explains Sepaintner. “But we can
design systems for up to 1,000 bar if needed, and there is essentially no upper limit.”
(left) Test system for diesel injectors: Flow analysis is performed here using the IAV Cross Injection Analyzer with various control configurations. Leak testing with a supply pressure of up to 3,000 bar is also possible. (right) Gasoline injectors can be tested on the test systems using spray tests, flow tests, leak testing, and optical inspection, among other methods.
Sonplas not only supports the development of complete test benches, but also the optimization of existing production lines. “Because we offer both assembly and testing from a single source, we provide a complete package,” notes Sales Engineer Sepaintner. “Having just one point of contact shortens communication paths, reduces organizational effort, and eliminates interface issues.”
Sonplas will therefore be the “last man standing.” Even in a changing market with growing e-mobility, the company continues to support its customers in the development and testing of conventional combustion technologies.
