Our Products Fuel Injection Technology
iThe trend is clear: In addition to battery-electric systems, combustion engines are once again gaining importance worldwide—not only in Europe, but especially in markets like the US and China. Governments and manufacturers are increasingly focusing on modern fuel injection systems to further improve efficiency and emissions standards.
Sonplas supports this technological shift with highly specialized special-purpose machines for the assembly and testing of fuel-contacting components, all from a single source. With its many years of automation expertise, the company provides manufacturers of injection systems with precise, reliable, and future-ready solutions.
For which components are the assembly and testing systems employed?
Sonplas develops and manufactures automated assembly and testing systems specifically designed for fuel-contacting components in injection systems:
- Valves
- Injectors and pressure regulators
- Fuel rails
- Injection pumps
- Pre-feed pumps
Which testing methods are available?
Our test benches handle typical processes such as testing flow rate, leak tightness, and spray pattern, as well as measuring opening and closing times and determining the injection rate. Both functional and endurance tests can be carried out on individual components as well as on the complete system.
- Our testing and automation solutions for the automotive industry provide precise data for analyzing and optimizing injectors, including opening and closing times, thereby enhancing the performance, efficiency, and reliability of your systems. In addition, our test bench enables the safe use of demanding test media, such as n-heptane, thanks to its explosion-proof components.
- Our automated test benches also ensure reliable evaluation of high-pressure pumps under realistic conditions. Measuring flow rate and operating pressure in relation to relevant operating parameters helps you maintain quality, shorten development times, and reduce costs.
- For testing spray hole components, our systems automate the entire process—from loading and unloading external processing equipment to detecting and measuring relevant component properties. This enables more efficient quality assurance and production workflows, reduces scrap, and lowers process costs.
Which assembly lines are available?
If required, our automated assembly lines integrate assembly, adjustment, and inline inspection processes to deliver efficient and reliable production workflows. Intelligent control systems and flexible buffer solutions ensure consistently high quality, minimize downtime, and enable the safe and reliable processing of large volumes so your production runs smoothly and cost-effectively.
Your benefit
While many market players have long since turned their backs on combustion technology, we continue to invest specifically in innovations in the fuel sector. We develop highly specialized assembly systems and test benches for components that come into contact with petrol or diesel. These are precise, reliable and future-proof. This makes us one of the few suppliers who still consistently promote this expertise today.
Our assembly and test benches feature a modular design and are tailored precisely to your specific requirements. This approach allows them to be expanded, upgraded, or adapted to changing conditions at any time. Units that are not needed can be omitted, ensuring maximum efficiency and functionality.
When designing and building our special-purpose machines for fuel-carrying components, we factor in all explosion protection requirements in compliance with ATEX right from the start. This ensures that your system operates legally compliant, safely, and in line with the latest state-of-the-art technology.
Our expertise doesn’t end with the construction of assembly and testing systems. From the planning phase onward, we provide comprehensive guidance on technical requirements, safety regulations, and standards-compliant design. During implementation, we focus on every detail and actively support you throughout the official or internal approval process. This ensures your system is commissioned smoothly and operates without issues.
Our systems are designed to meet today’s requirements for injection pressure, handling up to 500 bar. If needed, we can also deliver systems capable of 1,000 bar or even higher. Thanks to our flexible engineering approach, there are virtually no upper limits. Our injection nozzle test bench is specifically designed for the most demanding applications and has already been successfully deployed multiple times.
With our expertise, we are able to automate a wide range of processes in assembly and testing. To achieve this, we leverage our extensive experience from the fast-paced automotive industry.
How Sonplas can support you
As a manufacturer of special-purpose machines, we develop fully customized solutions with clear structures, minimal interfaces, and maximum efficiency. Where it adds value, we integrate proven third-party components, while deploying our own developments wherever standard solutions reach their limits. The result is highly flexible, high-performance, and cost-effective assembly and testing systems for fuel-carrying components.
Working together toward the ideal testing process
We develop your system in close collaboration with you, tailoring it to your components, testing requirements, and desired level of automation. Whether it’s a single station or a complete system, integration into an existing line or a brand-new installation, we deliver precisely engineered solutions that are perfectly aligned with your needs.
FAQ
The development time varies depending on complexity and customer requirements but typically ranges from a few weeks to several months.
Sonplas offers regular maintenance, inspections, fast technical support, and a reliable spare parts supply to ensure maximum system availability. With subsidiaries and service partners in China, the US, India, Brazil, Korea, Japan, Romania, Lithuania, and Italy, we provide comprehensive worldwide service and support.
In addition to complying with explosion protection requirements, Sonplas utilizes certified safety technologies, highly trained personnel, and comprehensive risk analyses to ensure maximum safety.
Yes, the modular systems are specifically designed to be easily integrated into existing production or testing lines.
The machines comply with common international standards, including ISO, CE marking, ATEX for potentially explosive environments, and other industry-specific regulations.
Sonplas focuses on minimizing fuel losses and optimizing test cycles to conserve resources and reduce emissions. In addition, we consistently rely on energy-efficient drives across all our systems, with all pressure generators powered electrically. This approach ensures low overall energy consumption and supports sustainable testing processes.
Sonplas continuously monitors current developments and offers flexible retrofits and updates for existing systems to ensure ongoing compliance with all regulatory and technical standards.
We provide hands-on training and detailed instruction to ensure the safe and efficient operation of the systems.
Generally, yes. Sonplas can adapt systems to different fuel types or develop new ones to meet customer needs.
Contact us!
B.Eng.
Sales
+49 9421 9275-362
info@sonplas.de
Lukas Sepaintner
Sales Engineer
Mr. Sepaintner, many manufacturers are moving away from combustion technology. Why does Sonplas continue to focus on this area?
Lukas Sepaintner: Because the market demands it—and that demand is growing. While many are focusing on electromobility, we are currently seeing a clear resurgence in demand for combustion engines, particularly in Europe, the US, and China. Modern injection systems, in particular, play a crucial role in improving efficiency and reducing emissions. Sonplas is one of the few suppliers continuing to actively invest in this area and we are among the “last men standing” in the industry.
How does this impact your machine solutions?
Lukas Sepaintner: We develop highly specialized assembly and testing systems for fuel-carrying components, such as valves, injectors, pumps, and pressure regulators. Our systems feature a modular design, are precisely tailored to customer requirements, and can be expanded or reconfigured at any time if needed.
How important is the combination of assembly and testing?
Lukas Sepaintner: Very important. We provide both assembly and testing from a single source, which saves our customers time, reduces coordination efforts, and eliminates unnecessary interfaces. The result is a seamlessly integrated, fully functional system that fits perfectly into existing production environments. This also gives our customers the advantage of having a single point of contact.
Are there technological limits when it comes to testing requirements?
Lukas Sepaintner: Practically none. Our systems currently operate with injection pressures of up to 500 bar, and we have already successfully implemented solutions for 1,000 bar and beyond on multiple occasions. Thanks to our highly flexible engineering, there are virtually no upper limits.