Diesel common rail technology is one of the most advanced technologies in the world's automobile industry. It is the only way for modern diesel power to go to high efficiency, energy saving and environmental protection. It is also the most important way for diesel vehicles to meet Euro IV and higher emission regulations. China's research on diesel common rail technology started late. After more than ten years of efforts by FAW Group, China has completed the research and trial production of common rail products. If we want to further develop the capacity of mass production, we must rely on independent research and development, systematic research. High-precision manufacturing technology, automatic detection technology for manufacturing whole process and product assembly, development of advanced special equipment, and automatic test system and related technical standards for mass production of key products of common rail system. This work has no time to delay. If the testing technology in the manufacturing process is not studied in time and the special automatic testing equipment is developed, it is impossible to realize the transformation from product research to industrialization. Without advanced automatic detection technology and complete sets of special equipment as the basis, product innovation Can only stay in the sample stage.
The common rail injector is the core component of the diesel common rail system. The manufacturing precision of the product has greatly improved the precision requirements of the components compared with the traditional products. It relies on high-precision machining to complete the reliable mass production of the products. One of the prerequisites for the mass production of common rail injectors is the efficient and reliable high-precision inspection equipment that can perform 100% inspection and sorting on site during manufacturing and assembly. Only through the full inspection of key geometric quantities and performance can the consistency and reliability of the manufacturing process and product quality be guaranteed.
With the support of major national science and technology projects, our company cooperated with FAW Group Wuxi Oil Pump Nozzle Research Institute to systematically study the detection technology in the manufacturing process of common rail injectors in China, and will form a manufacturing process with common rail injectors. Combined product quality assurance system. The research and equipment development of the automatic detection technology of the common rail injector assembly is one of the most important research contents.
The significance of the development work
The reason why the diesel-electric control common rail technology can achieve energy saving and environmental protection is that the common rail injector can be combined with its high-precision, high-speed actuator through the electronic control of the ECU to achieve precise injection of fuel timing. If the fluctuation of the fuel injection quantity deviation exceeds a certain value, the injector injection inconsistency will not be corrected by the software in the ECU, resulting in uneven oil volume in the engine cylinders, causing engine vibration, noise and Pollutants are discharged and may not even work properly. Therefore, each common rail injector must undergo strict injection performance test before leaving the factory, including injector single injection oil quantity, single injection oil quantity standard deviation, opening pressure, multiple injection law and return oil. Measurement of the performance parameters such as quantity , these data are not only the basis for judging the consistency and stability of the injector quality, but also an important parameter for engine testing and debugging.
Mass production of common rail injectors must be ensured by high-efficiency, high-reliability, high-precision automatic inspection equipment. The automatic inspection equipment for common rail injector assembly performance is an essential equipment for the production of common rail injectors.
The company that manufactures automatic test equipment for common rail injector assembly performance mainly includes France EFS Company, Italy LOCCIONI Company, Germany IAV Company and Germany Moehwald Company. The common feature of these companies are both international mainstream fuel injection system manufacturers have close cooperation, the method of measuring the fuel injection fuel long-term studies, a single injection to gauge their own technology as the core to form a common rail injector total The performance is automatic detection equipment, but it is expensive, especially the price and technical service cost of the single injection measuring instrument are high. If Chinese enterprises rely on the introduction of automatic testing equipment or the introduction of single-shot measuring instruments to meet the needs of batch testing of common rail injectors, they obviously lose market competitiveness.
The technical development trend of the automatic detection equipment for foreign common rail injector assembly performance is mainly as follows:
(1) Continuously study the high-speed measurement method of single minute flow to form a high-precision high-frequency single-shot measuring instrument. At present, the single-flow measurement accuracy has been improved to ±0.2 mm3, and it is possible to measure up to 10 small injections per cycle. characteristic.
(2) Continuously improve the intelligence and automation level of the equipment. Due to the performance test, the test pressure is as high as 200 MPa. The traditional equipment uses the manual injector to measure the fuel injector, which is less efficient. At present, the automatic detection equipment for the assembly performance applied in the mass production process has become a trend by adopting an automatic clamping of the fuel injector to be tested and automatically sealing the high-pressure test fuel. At the same time, in the automatic measurement process, no manual intervention is required; the computer software technology and barcode technology are fully applied to form the intelligence and traceability of the assembly performance evaluation.
2. Status of domestic technology and equipment
China has a number of companies that produce fuel injector assembly performance testing equipment, but the fuel injector assembly performance testing equipment produced by the company basically stays in the measuring cup method or the measuring cup weighing method, that is, the fuel injecting from the injector into the measuring cup. The amount of fuel injected is measured by measuring the cup scale or weighing. This type of equipment can only measure the cumulative injection flow rate multiple times, and the average calculation of the single injection fuel quantity can not meet the performance requirements of the common rail injector assembly.
In general, China's research on the performance testing equipment for common rail injector assembly started very late. At present, the common rail injector assembly performance testing equipment developed by individual enterprises is purchased from foreign single-shot measuring instruments. The core measurement technology without independent intellectual property rights is subject to people. Moreover, the level of automation and intelligence is low, and the gap with foreign equipment is very large.
Develop technical routes and technological innovations
The research on automatic detection equipment for common rail injector assembly performance is difficult. I adopted the technical route of modular research. Through the in-depth understanding of the structural and performance testing requirements of common rail injectors, the flow metering module was studied. Through a large number of experimental demonstrations, the comparison test of different modules determined the volume flow measurement. Structure and algorithm, and then study the key modules of automatic clamping technology and machine structure in turn, developed a common rail injector assembly performance test bench with independent intellectual property rights, with the following two technical breakthroughs and innovations:
(1) Automatically clamping two common rail injectors to achieve automatic high oil pressure injection and automatic and reliable sealing. The workpiece to be tested only needs to be placed in the positioning seat. The equipment can realize the automatic operation process from clamping, measuring to unloading. Without manual intervention, the measurement data is in one-to-one correspondence with the scanned two-dimensional code of the workpiece, and is automatically stored in the computer database. Among them, there are query, statistics and analysis functions. The expert system automatically analyzes the performance data of the common rail injectors tested, and automatically judges and displays whether the performance of the tested common rail injectors is qualified.
(2) flow rate measurement instrument module i.e. a single injection, the injection quantity per cycle can be achieved, the injection rate of each injection in the small injection up to 5 times, on delay, the delay measured off, parameters such as the duration, and The fuel injection law can be displayed in real time in a dynamic curve.
In the breakthrough of core technology, we strive to reach the international advanced level, carefully study the world's existing common rail injector assembly performance testing equipment and international cutting-edge technology, and combine the status quo of domestic common rail injector production testing, research and development A variety of technical solutions, repeated experimental research, and finally formed a device that can effectively control costs and meet the needs of injector production.
Conclusion
For the development of automatic detection equipment for common rail injector assembly performance, we have been closely tracking the development of new international technologies. At present, we have broken through a number of key technologies and developed a common rail injector assembly performance test bench. Work is of great value for breaking foreign technology monopoly and blockade.
The rapid development of China's automobile industry urgently requires the improvement of the technological level and innovation capability of China's equipment manufacturing industry. On the basis of learning advanced foreign technology, it is necessary to independently innovate and develop high-end equipment with independent intellectual property rights.
The common rail injector is the core component of the diesel common rail system. The manufacturing precision of the product has greatly improved the precision requirements of the components compared with the traditional products. It relies on high-precision machining to complete the reliable mass production of the products. One of the prerequisites for the mass production of common rail injectors is the efficient and reliable high-precision inspection equipment that can perform 100% inspection and sorting on site during manufacturing and assembly. Only through the full inspection of key geometric quantities and performance can the consistency and reliability of the manufacturing process and product quality be guaranteed.
With the support of major national science and technology projects, our company cooperated with FAW Group Wuxi Oil Pump Nozzle Research Institute to systematically study the detection technology in the manufacturing process of common rail injectors in China, and will form a manufacturing process with common rail injectors. Combined product quality assurance system. The research and equipment development of the automatic detection technology of the common rail injector assembly is one of the most important research contents.
The significance of the development work
The reason why the diesel-electric control common rail technology can achieve energy saving and environmental protection is that the common rail injector can be combined with its high-precision, high-speed actuator through the electronic control of the ECU to achieve precise injection of fuel timing. If the fluctuation of the fuel injection quantity deviation exceeds a certain value, the injector injection inconsistency will not be corrected by the software in the ECU, resulting in uneven oil volume in the engine cylinders, causing engine vibration, noise and Pollutants are discharged and may not even work properly. Therefore, each common rail injector must undergo strict injection performance test before leaving the factory, including injector single injection oil quantity, single injection oil quantity standard deviation, opening pressure, multiple injection law and return oil. Measurement of the performance parameters such as quantity , these data are not only the basis for judging the consistency and stability of the injector quality, but also an important parameter for engine testing and debugging.
Mass production of common rail injectors must be ensured by high-efficiency, high-reliability, high-precision automatic inspection equipment. The automatic inspection equipment for common rail injector assembly performance is an essential equipment for the production of common rail injectors.
Domestic and foreign technology status
1. Status of foreign technology and equipment
The company that manufactures automatic test equipment for common rail injector assembly performance mainly includes France EFS Company, Italy LOCCIONI Company, Germany IAV Company and Germany Moehwald Company. The common feature of these companies are both international mainstream fuel injection system manufacturers have close cooperation, the method of measuring the fuel injection fuel long-term studies, a single injection to gauge their own technology as the core to form a common rail injector total The performance is automatic detection equipment, but it is expensive, especially the price and technical service cost of the single injection measuring instrument are high. If Chinese enterprises rely on the introduction of automatic testing equipment or the introduction of single-shot measuring instruments to meet the needs of batch testing of common rail injectors, they obviously lose market competitiveness.
The technical development trend of the automatic detection equipment for foreign common rail injector assembly performance is mainly as follows:
(1) Continuously study the high-speed measurement method of single minute flow to form a high-precision high-frequency single-shot measuring instrument. At present, the single-flow measurement accuracy has been improved to ±0.2 mm3, and it is possible to measure up to 10 small injections per cycle. characteristic.
(2) Continuously improve the intelligence and automation level of the equipment. Due to the performance test, the test pressure is as high as 200 MPa. The traditional equipment uses the manual injector to measure the fuel injector, which is less efficient. At present, the automatic detection equipment for the assembly performance applied in the mass production process has become a trend by adopting an automatic clamping of the fuel injector to be tested and automatically sealing the high-pressure test fuel. At the same time, in the automatic measurement process, no manual intervention is required; the computer software technology and barcode technology are fully applied to form the intelligence and traceability of the assembly performance evaluation.
2. Status of domestic technology and equipment
China has a number of companies that produce fuel injector assembly performance testing equipment, but the fuel injector assembly performance testing equipment produced by the company basically stays in the measuring cup method or the measuring cup weighing method, that is, the fuel injecting from the injector into the measuring cup. The amount of fuel injected is measured by measuring the cup scale or weighing. This type of equipment can only measure the cumulative injection flow rate multiple times, and the average calculation of the single injection fuel quantity can not meet the performance requirements of the common rail injector assembly.
In general, China's research on the performance testing equipment for common rail injector assembly started very late. At present, the common rail injector assembly performance testing equipment developed by individual enterprises is purchased from foreign single-shot measuring instruments. The core measurement technology without independent intellectual property rights is subject to people. Moreover, the level of automation and intelligence is low, and the gap with foreign equipment is very large.
Develop technical routes and technological innovations
The research on automatic detection equipment for common rail injector assembly performance is difficult. I adopted the technical route of modular research. Through the in-depth understanding of the structural and performance testing requirements of common rail injectors, the flow metering module was studied. Through a large number of experimental demonstrations, the comparison test of different modules determined the volume flow measurement. Structure and algorithm, and then study the key modules of automatic clamping technology and machine structure in turn, developed a common rail injector assembly performance test bench with independent intellectual property rights, with the following two technical breakthroughs and innovations:
(1) Automatically clamping two common rail injectors to achieve automatic high oil pressure injection and automatic and reliable sealing. The workpiece to be tested only needs to be placed in the positioning seat. The equipment can realize the automatic operation process from clamping, measuring to unloading. Without manual intervention, the measurement data is in one-to-one correspondence with the scanned two-dimensional code of the workpiece, and is automatically stored in the computer database. Among them, there are query, statistics and analysis functions. The expert system automatically analyzes the performance data of the common rail injectors tested, and automatically judges and displays whether the performance of the tested common rail injectors is qualified.
(2) flow rate measurement instrument module i.e. a single injection, the injection quantity per cycle can be achieved, the injection rate of each injection in the small injection up to 5 times, on delay, the delay measured off, parameters such as the duration, and The fuel injection law can be displayed in real time in a dynamic curve.
In the breakthrough of core technology, we strive to reach the international advanced level, carefully study the world's existing common rail injector assembly performance testing equipment and international cutting-edge technology, and combine the status quo of domestic common rail injector production testing, research and development A variety of technical solutions, repeated experimental research, and finally formed a device that can effectively control costs and meet the needs of injector production.
Conclusion
For the development of automatic detection equipment for common rail injector assembly performance, we have been closely tracking the development of new international technologies. At present, we have broken through a number of key technologies and developed a common rail injector assembly performance test bench. Work is of great value for breaking foreign technology monopoly and blockade.
The rapid development of China's automobile industry urgently requires the improvement of the technological level and innovation capability of China's equipment manufacturing industry. On the basis of learning advanced foreign technology, it is necessary to independently innovate and develop high-end equipment with independent intellectual property rights.
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