Fuel Pump Test Rig

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Technical Details

Specifications

Component	Specification & Details
Control Platform	Industrial PC (Intel i7, 16 GB RAM, RAID-1 SSD) with LabVIEW™ 2021 SP1; secure VPN remote-access option
PLC & I/O	Siemens S7-1500 + ET 200SP: 64 DI/DO, 32 AI/AO channels
Flow Range	0–250 L/min (turndown to 0.1 L/min); ±0.2 % full-scale accuracy
Pressure Range	0–350 bar (standard), optional 0–400 bar; ±0.5 % accuracy
Temperature Control	PID-controlled jacket (–20 °C to +120 °C) with ±0.5 °C stability
Data Logging	Up to 1 kHz/channel, local SSD or NAS storage; SQL integration with retention-policy management
Materials	SS 316L tubing & fittings, Viton® seals; optional PTFE lining for biofuel compatibility
Valving	Five 24 VDC solenoids; three manual needle valves; optional motorized proportional valves for smooth ramp profiling
User Interface	21” touchscreen HMI with multilingual GUI (EN, DE, FR); keyboard/mouse and RDP access
Footprint & Utilities
1.8 m × 0.9 m × 1.5 m (L × W × H), 650 kg; power: 400 VAC, 50 Hz, 3×20 A; services: 5 kW chiller, 6–8 bar compressed air

Applications

Automotive R&D & Production
▹Simulates engine crank-shaft coupling for gear and vane pumps, including pulsation patterns and thermal transients.
▹Overnight endurance runs (up to 100 hours) with auto-filtration to maintain fluid clarity and protect pump internals.

Aerospace & Defense
▹Meets MIL-STD-810G for vibration and DO-160G for thermal cycling; suitable for first-article inspection and certification testing.
▹Generates AS9102 FAI reports, including dimensional and performance verification.

Industrial Machinery
▹Validates fuel-injection units in generators, compressors, and marine propulsion systems under adjustable load profiles.
▹Custom cycle creation replicates on-off duty cycles, ramp/dwell sequencing, and simulated altitude conditions (via optional pressure chamber).

Quality Control & Calibration Labs
▹Batch testing with barcoded part IDs, operator signatures, and encrypted logs to comply with ISO 9001 and IATF 16949.
▹Built-in sensor calibration routines with automated certificate printing, reducing downtime between verification cycles.

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Details

Introduction
The Neometrix Fuel Pump Test Rig is a fully integrated, PLC-controlled platform designed to execute comprehensive performance and endurance tests on rotary, reciprocating, and diaphragm-type fuel pumps. At its heart sits an industrial PC running a LabVIEW™-based control and data-acquisition suite, which coordinates dynamic load simulations, temperature cycling, and safety interlocks without operator intervention. Tests—from cold-start validation at –20 °C to high-temperature endurance at +120 °C—can be queued and run unattended, with automated self-diagnostics, alarm thresholds for over-pressure/over-temperature, and real-time condition monitoring via vibration and ultrasonic flow sensors

Key Features
▹ PLC-Driven Automation: Siemens S7-1500 PLC with preloaded and custom pump test recipes for precise, deterministic cycle control.
▹ High-Fidelity Data Acquisition: 16-bit, 1 kHz sampling on 32 channels with live waveform display, metadata tagging, and SQL/NAS export.
▹ Advanced Fluid Handling: SS 316L wetted path, 0–250 L/min closed-loop flow at 350 bar with ±0.2 % repeatability and PID thermal control.
▹ Modular Valve & Sensor Suite: 5-way solenoid manifold, manual needle valves, and optional ultrasonic flow or vibration sensor modules.
▹ Safety & Compliance: Enclosed chamber with interlocks, emergency venting, CE/UL-listed components, and ASTM/ISO/cGMP adherence.

Technical specifications

  
    Component
    Specification & Details
  
  
    Control Platform
    Industrial PC (Intel i7, 16 GB RAM, RAID-1 SSD) with LabVIEW™ 2021 SP1; secure VPN remote-access option
  
  
    PLC & I/O
    Siemens S7-1500 + ET 200SP: 64 DI/DO, 32 AI/AO channels
  
  
    Flow Range
    0–250 L/min (turndown to 0.1 L/min); ±0.2 % full-scale accuracy
  
  
    Pressure Range
    0–350 bar (standard), optional 0–400 bar; ±0.5 % accuracy
  
  
    Temperature Control
    PID-controlled jacket (–20 °C to +120 °C) with ±0.5 °C stability
  
  
    Data Logging
    Up to 1 kHz/channel, local SSD or NAS storage; SQL integration with retention-policy management
  
  
    Materials
    SS 316L tubing & fittings, Viton® seals; optional PTFE lining for biofuel compatibility
  
  
    Valving
    Five 24 VDC solenoids; three manual needle valves; optional motorized proportional valves for smooth ramp profiling
  
  
    User Interface
    21” touchscreen HMI with multilingual GUI (EN, DE, FR); keyboard/mouse and RDP access
  
  
    Footprint & Utilities
  
  
    1.8 m × 0.9 m × 1.5 m (L × W × H), 650 kg; power: 400 VAC, 50 Hz, 3×20 A; services: 5 kW chiller, 6–8 bar compressed air
  


Applications
Automotive R&D & Production
▹ Simulates engine crank-shaft coupling for gear and vane pumps, including pulsation patterns and thermal transients.
▹ Overnight endurance runs (up to 100 hours) with auto-filtration to maintain fluid clarity and protect pump internals.

Aerospace & Defense
▹ Meets MIL-STD-810G for vibration and DO-160G for thermal cycling; suitable for first-article inspection and certification testing.
▹ Generates AS9102 FAI reports, including dimensional and performance verification.

Industrial Machinery
▹ Validates fuel-injection units in generators, compressors, and marine propulsion systems under adjustable load profiles.
▹ Custom cycle creation replicates on-off duty cycles, ramp/dwell sequencing, and simulated altitude conditions (via optional pressure chamber).

Quality Control & Calibration Labs
▹ Batch testing with barcoded part IDs, operator signatures, and encrypted logs to comply with ISO 9001 and IATF 16949.
▹ Built-in sensor calibration routines with automated certificate printing, reducing downtime between verification cycles.

Benefits & Value Proposition
Throughput Optimization
▹ Recipe chaining and auto-changeover cut per-test setup by up to 70 %, allowing high-volume labs to process more parts with the same workforce.

Data Integrity & Traceability
▹ Tamper-proof, ISO-compliant audit trails; customizable retention and backup policies support both internal QA and external regulatory audits.

Scalable Architecture
▹ Modular I/O and software-defined channels facilitate future expansion—add new sensor types or test modes (e.g., cavitation mapping, viscosity-based profiling) without a hardware overhaul.

Durable Reliability
▹ Industrial-grade components rated for 24/7 operations; SS 316L construction resists corrosion from ethanol, biodiesel, and specialty fuels, minimizing maintenance frequency.

Conclusion
By uniting precision hardware, adaptable software, and stringent safety design, the Neometrix Fuel Pump Test Rig provides a comprehensive, future-proof platform for fuel-pump validation. Its robust feature set—ranging from automated recipe execution and high-speed data logging to modular sensor integration and certified reporting—ensures that R&D teams, production facilities, and calibration labs alike can achieve higher throughput, flawless data integrity, and full compliance with global standards. Whether the goal is rigorous endurance testing, first-article certification, or high-volume quality control, this turnkey solution delivers the flexibility and performance to meet evolving industry demands.