BC-NJ Common Rail Injector Endurance Test Bench

1. Product Overview

The BC-NJ Common Rail Injector Endurance Test Bench is designed by BEACON for endurance (running-in) testing of electronically controlled fuel injector assemblies on the production line. It is the standard equipment used by OEM injector manufacturers (Bosch, Denso, Delphi, Siemens and Chinese brands) to verify the durability, sealing, atomization and lifetime of newly manufactured common rail injectors before they leave the factory.

2. 8-Station Simultaneous Testing

The BC-NJ integrates 8 independent electronically controlled injector drive channels, allowing 8 injectors to be tested simultaneously under the same or different working conditions. Each station has its own drive, return circuit and data acquisition. This greatly increases the throughput of the production line while keeping the bench footprint compact.

3. High Pressure Rail System

The high-pressure oil source is generated by a motor-driven Bosch common rail pump through a durable coupling with safety enclosure. Maximum rail pressure reaches 300 MPa, and the rail pressure is monitored by a high-pressure sensor with 0-350 MPa range and 0.5 % accuracy class mounted on the self-made common rail pipe.

4. Main Drive Motor & Inverter

The main drive motor is 3-phase, 380 V, 50 Hz, 11 kW with a speed range of 40 to 1450 r/min. The inverter power matches the inverter motor precisely, and the control system calculates the motor speed according to the set injection quantity, ensuring stable rail pressure under varying injection loads.

5. Closed Oil Return Circuit

The injector return oil adopts a closed return circuit with an open-type filter in the return line. After endurance testing the medium is filtered and flows back to the 60 L fuel tank, reducing oil consumption and keeping the test environment clean.

6. Two-Stage Fuel Filtration

Fuel filtration is divided into two stages: a 200-mesh coarse filter inside the fuel tank, and a 5 µm high-precision standard filter installed between the fuel tank and the common rail pump inlet. This protects the high-pressure pump and injectors from particle damage during long-duration tests.

7. Temperature Control & Cooling

Fuel temperature is controlled within 40 °C to 50 °C by a refrigeration unit (forced cooling). The closed operating space is equipped with fluorescent lighting and a protective cover. Installation environment temperature is 5 to 35 °C, relative humidity 20 to 90 % RH without condensation.

8. Control System & Data Acquisition

The control system allows the operator to set rail pressure, waiting time, injection quantity and test duration. It automatically calculates the motor speed according to the injection quantity setpoint, and records cycle counts, pressure curves and alarm events for each of the 8 stations. Test data can be exported for SPC analysis and quality traceability.

1. Comprehensive Production Line Solution - The BC-NJ common rail injector endurance test bench is purpose-built for OEM injector manufacturers, supporting 8 injectors tested simultaneously under independent drive circuits, dramatically improving throughput versus single-station testers used in repair shops.

2. Industrial-Grade High Pressure Capability - With Bosch common rail pump drive and maximum rail pressure of 300 MPa, the BC-NJ endurance test bench fully covers the working pressure range of all current Euro V/VI, EPA Tier 4 Final and China NSVI common rail systems, ensuring realistic running-in conditions for new injectors.

3. Precision Pressure Monitoring - A high-pressure sensor with 0-350 MPa range and 0.5 % accuracy class is mounted on the self-made common rail pipe, providing real-time rail pressure feedback for each test cycle and supporting long-duration endurance testing up to millions of injection cycles.

4. Closed-Loop Oil Return & Two-Stage Filtration - The 60 L fuel tank with 200-mesh coarse filter plus 5 µm high-precision inlet filter keeps the test medium clean during long-term running-in, while the closed oil return circuit with in-line filter minimizes oil consumption and protects the test environment.

5. Intelligent Control System - The integrated control system automatically calculates motor speed from the injection quantity setpoint, supports programmable rail pressure, waiting time and test duration per station, and exports cycle count and pressure curve data for SPC analysis and full traceability.

6. BEACON Global Service & Customization - Backed by BEACON's worldwide technical support and 1-year warranty, the BC-NJ bench can be customized for special injector types and OEM production line layouts, with installation, commissioning and operator training available in English, Spanish, Russian and Chinese.