HeNan Perfect Auto Part co.,Ltd
The professional factory with 10 years history.
Production line of common rail injector
Needle valve body manufacturing process
Step 1: Needle valve blank drilling
Our introduction begins with the blank of the needle body. The four-axis gun drilling machine imported from Germany is used for rough machining of the needle body blank, the four-axis gun is drilled once, and the hole in the injector is formed once.
This is the way after processing, and the one-time forming can ensure the concentricity, straightness and roughness meet the requirements.
Step 2: Processing the needle valve body hole position
Next, this equipment is a vertical machining center imported from the United States. It is used to machine the hole positions of the needle valve body. The fuel nozzle processes two positioning holes and one oil inlet hole through it.
Step 3: Electrochemical Electrolytic Oil Tank
This step is an electrochemical electrolysis oil sump that ensures the size of the oil sump while ensuring that there are no burrs.
The original process is to use a knife to extend into the digging. For products with extremely high precision such as the injector, the disadvantage is that there are more burrs and irregular shapes. The use of electrochemical electrolysis can solve this problem very well.
Step 4: Spray hole processing
At present, the typical process is a micro-hole EDM process. The Swiss-made CNC micro-hole EDM machine is used. The flow accuracy is ±3%, and the precision of the injection hole is very high.
In order to ensure the injection pressure and effect of the injector, the accuracy of the injection hole is very high. The orifice should be inverted and tapered to help increase the orifice flow coefficient and enhance the spray effect.
Step 5: Extrusion grinding
Next, using the American-made extrusion grinding equipment, the flow rate of the squeeze needle valve body is detected online to reach the flow standard, and the error is controlled within ±1%. At the same time, there is deburring effect, which can reduce the pressure loss of the nozzle.
The extrusion grinding equipment detects the interface and the error is controlled within ±1%.
Step 6: Traffic Detection
Flow rate detection is performed on the processed needle valve body, and the valve body of each nozzle is 100% tested for flow consistency.
The one we saw was the flow meter, which is also the highest level of testing equipment in the country.
In addition, in order to better understand whether the injector can meet the needs under actual working conditions, it is also necessary to test the injector and the original injector after installation. This is the Italian common rail injector test bench. The function is to test the technical parameters of each working condition after installation with the original injector.
Step 7: Processing the hole seat surface and the large end surface
What we see here is the German-made CNC high-precision mesoporous grinding machine. It is used to machine the middle hole, seat surface and large end face of the needle valve body.
Automatic loading and unloading can be realized in one clamping, which ensures the accuracy and coaxiality of each part. In addition, the large end face is indented after fine grinding, which is advantageous for assembly and sealing with the injector body.
Next, let's take a look at another important component of the injector – how the needle valve is processed.
Step 1: The needle valve is roughened into a blank
After the heat-treated needle valve is roughly ground, a blank is formed, and fine grinding is continued in the subsequent process.
Step 2: Detect the needle blank size
First of all, it is necessary to check and confirm the size of the needle valve blank, and enlarge it by the projector to ensure the precise cooperation with the needle valve body.
Step 3: Processing the needle angle
The detected needle valve was sent to a German CNC high-precision cylindrical grinding machine for processing. This step is mainly to process the angle of the folding method.
Simultaneous grinding at multiple angles in one setup. The benefit of one-time machining is to ensure the concentricity of the needle head angle and the needle guide circle, as well as the consistency and stability of the needle head seal line size.
Needle valve being prepared for processing
Step 4: Cut the needle valve size outer circle
Finally, the outer diameter of the needle valve needs to be cut, which is done by a CNC high-precision coreless grinding machine made in Italy. The roundness of the needle valve needs to be controlled above 0.25μm in order to meet the accuracy requirements of the common rail injector.
After the processing of the above several steps, the valve body and needle valve of a fuel injector are initially processed.
The next step is to transfer the needle valve and valve body to the mating part for the fitting test of the coupling part. Because some technical confidentiality procedures are involved, the work content of the mating department is not reflected here, and the final is the packaging stage.
This is a well-made nozzle nozzle, the needle valve and the needle valve body form a pair of precision couples, and the clearance requirements are extremely high. Strictly speaking, it cannot be changed during use, but the current processing accuracy can guarantee the interchange of the same batch of products.
For processed injectors, a sampling check is also required to ensure that each batch of product meets the accuracy requirements.
What we are seeing now is a shape measuring instrument imported from Germany, which mainly detects the roundness, cylindricity and inclination angle of the nozzle, ensuring that the indexes meet the requirements and meet the stringent precision of the common rail injector. Claim. The product can be packaged after all steps have been completed.
He Nan Perfect Auto Part co.,Ltd is a professional factory with 10 years history.
We passed ISO/TS 16949:2002 certification.We have advanced equipment, testing machine and management system.Our products have been exported to Europe , USA, Centraland south America, Southeast Asia, Mid East ,Africa , etc.
Mainly producing and selling: diesel nozzle, common rail injector assembly, fuel injector nozzle nut, injector repair kits, common rail valve, valve cap, injector shims and washers, injector ball and ball seat, injector solenoid valve,spring, o-ring, and so on.
We have a strong R& D and corporate management teams and improve the management system.In the technology has its own R& D team and intellectual property.We have products with competitive prices and high quality.
The company independently develops and designs new products, and the product line is rich.The company's technical support and R& D capacity in the industry is first-rate.In the technology has its own R& D team and intellectual property.
Contact Person: Mr. Wang