For a customer from the automotive engineering sector we developed a dynamical pressure test unit up to 3000 bar.
This dynamical pressure test unit PRO3000HY with hydraulic pressure up to 3000 bar is used for the tests of pressure sensors of “Common- Rail”– systems (memory injection systems).
Problem:
The pressure sensors used in Common-Rail-Systems has to meet very high requirements for measurement accuracy, environmental conditions and longevity.
To verify the quality of the sensors the PRO3000HY is simulating the pressure curves with which the sensors (specimens) are applied.
Additionally to the static pressures for calibration, also dynamical pressures curves must be possible to be simulated.
Unit concept:
The hydraulic pressure test unit PRO3000HY allows a PC operated pressure increase up to 3000 bar. The output pressure is generated via pressure transducers, that means a regulated hydraulic pre-pressure is driving the pressure transducer which converts it into the hydraulic secondary pressure. Leakages and air inclusions are regulated. Test oil is refilled.
A hydraulic power unit supplies the pre-pressure, buffered by a pressure accumulator. The pressure is hold in the range between 260 and 300 bar.
This pre-pressure is set on a pressure transducer by a hydraulic control system.
The conversion factor 1:12 realizes a secondary pressure of up to 3000 bar.
The hydraulic primary circulation consists of: A storage tank, a motorized hydraulic pressure pump, a filter, a cooling unit, various valves and a servo or control valve. The output of the control valve is connected to the primary side of the pressure transducer.
The hydraulic secondary circulation consists of: A storage tank, a motorized hydraulic pressure pump, a relief valve, a burst disc, a pressure transducer on secondary side, various valves and the pressure adaptor and reference pressure sensor.
For operating and monitoring the unit, further components are added to allow a largely automized handling.
In a failure case the test unit switches off and the status bits are reporting the results so that an external software can react to them. The components of the unit are mounted in console housings with the dimensions: appr. 130x100x50cm (WxHxD).
The console housings can be opened at the top: On the right side you find the digital display “system pressure 3000 bar”, the control lights of the hydraulic pump, the button “door open” and the button “vent” (filling). At the right side part you can find the control slot and the manual drain valve, on the left side there is a stainless steel tub for the specimen adaptor.
The electrical contacting of the specimens is carried out by three rearward inlay connections.
In the stainless steel tub the pressure connection is placed on the right side. On the opposite side you can find a small opening. With a corresponding piping connection it is able to adapt external specimens e.g. in a climate chamber.
Software:
A micro-controller M4A is integrated in the testing unit operation which enables the communication with a PC via RS232 interface.
The software – written in ©LAB-VIEW – provides the PRO3000HY as a “virtual instrument” to the other program modules.
Calibration and service functions of the PRO3000HY itself are performed by a software or a terminal program via interface. An example is the linearization of the reference pressure transducer.
Summary:
- Measuring range: 0..3000 bar
- Reference pressure sensor: <0,1% of full scale, with characteristic curves linearization: <0,05% of full scale
- Pressure simulation:
- Static: 0..3000 bar
- Dynamical rectangular: 200..2500 bar, appr. 1,5 Hz
- Dynamical sinus: 200..2500 bar, appr. 0,8..1,2 Hz
- Ramp function available
- Medium: diesel test oil, separated from the pressure supply
- Piping: stainless steel, with stainless steel tub
- Venting: additional test oil pump
Please contact us for further information!
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