Flexible small series test bench for switching valves

The project

We were able to implement a test bench for switching valves specially developed for small series for our customer MSG. This innovative solution combines precision, efficiency and flexibility to optimize the testing and laser marking of switching valves. The test bench was initially designed for two valve types, but can be easily adapted to other valve types.

The system works with a maximum cycle time of 60 seconds per component (depending on the test duration of the measuring devices). This ensures fast and precise quality control – a decisive advantage in small series production.

• Flexibility: The test bench can be quickly and easily adapted to new valve types.
• Efficiency: Thanks to precise measuring methods, minimal set-up times and optimized data evaluation, reliable test results are achieved with low energy and time consumption.
• Precision: Only switching valves that have been tested and classified as “IO” (OK) are clearly labeled by laser.
• User-friendliness: An intuitive operating concept enables easy handling.
• Software: The integrated AUTFORCE software solution “autfactory” ensures reliable control and comprehensive data acquisition.

What are switching valves?

Switching valves are indispensable components in hydraulic and pneumatic systems. They control and regulate the flow of media such as air, water or oil and are used in various sectors, e.g. in the automotive industry, mechanical engineering and the process industry.

Preparation

The operator opens the safety gate manually and inserts the switching valve into the test adapter.

Contacting

Contacting the valve, both via electrical and pneumatic connections, is done manually in this case, but can also be done automatically, depending on the specific test requirements. For pneumatic tests, it is necessary for the valve connections to be “open” in order to be able to carry out leak tests properly.

Testing

The test bench carries out a series of specific tests:

• Resistance measurement: Checking the electrical resistance to ensure conductivity.
• Insulation test: Checks whether unwanted current flows due to insulation faults are excluded.
• Flow measurement: Checks whether the switching valve is regulating the flow correctly.
• Leak test: To ensure that the valve has no leaks.
• Stroke test: Measurement of the movement path of the moving components in the valve. This checks whether the valve opens sufficiently and whether the measured stroke meets the specified requirements.
• Valve switching: Checking the correct functionality in various switching states.

Laser marking

Switching valves classified as “IO” are clearly marked with specific component data and a DMC code (Data Matrix Code) for traceability.

Release and removal

After a successful test, the safety gate is released and the tested switching valve is removed.