To verify long-term durability of the components under high pulsating stresses it is essential to carry out an endurance test of the individual high-pressure components, as well as of the complete Common-Rail system. For this purpose, a pulsation test-rig is used, in which a pulsating pressure is applied to a Common-Rail system within specified limits (Figure left) and using a test liquid. The objective of such a test is to verify that a specified, maximum stress, can be continuously sustained during operation.
The major components of a pulsation unit are a high pressure pump, a pressure reservoir, switching valves with control and flow control valves, in the event that the pressure is not completely dissipated. Due to the high pressures (usually >1000 bar), the components of the test facilities as well as the test liquid must be selectively cooled.
The pulsation test rig at FUCHS DIESEL COMPONENTS PRODUCTION in Henggart provides continuous testing of a complete Common-Rail connection system for V-engines with up to 20 cylinders. Currently, pulsation tests are being carried out with pressure fluctuations up to 3100 bar. The pressure flow is measured, recorded and continuously stored using an in-house developed diagnostic tool (The Doctor, Figure right).