Modular Enclosure Test Stand for Portable Fuel Filtration System

Advanced Fuel Injector Testing Equipment for High-Pressure OEM Calibration

When a leading OEM supplier of filtration products needed to elevate its research and development capabilities, it faced the challenge of packing extreme high-pressure performance and precise particulate testing into an existing lab footprint. ACS delivered a fully integrated, turnkey solution that set a new global benchmark for the company’s testing operations.

The Challenge

An OEM supplier of filtration products for the on- and off-highway vehicle market needed to expand its testing capabilities to validate its product line across a variety of demanding applications. The company’s goal was to effectively evaluate how dust contamination impacts equipment longevity, requiring a highly specialized, customizable portable fuel filtration system setup. However, the project presented significant space and safety constraints. The new equipment had to fit perfectly within an existing test lab space, utilizing the building’s current utilities and infrastructure without requiring a costly facility expansion.

Because the testing procedures involved operating high-pressure fuel pumps and injectors up to 40,000 psi using volatile diesel calibration fluid, the environment introduced severe fire and safety hazards. Incorporating specialized diesel conditioning filter systems into what began as a conceptual system of skids quickly required a more comprehensive, structurally sound engineering approach to mitigate risks while maximizing space efficiency.

The Solution

The ACS team engineered a complete modular test cell enclosure that integrated all necessary mechanical, fluid, and safety systems into a single cohesive unit. At the core of the solution, ACS designed, built, and programmed an advanced fuel filtration system capable of blending an ISO standard dust into the working diesel calibration fluid to create a precise “dirty fuel” mixture. To ensure total operational safety under extreme pressures, ACS incorporated a fire-rated enclosure and a dedicated safety system into the modular unit.

The control architecture was designed for precision and rapid deployment. The comprehensive diesel conditioning filter systems utilize standalone temperature controllers to temper the fluid within the sump tanks, while data points for temperatures, pressures, and flows are continuously monitored. To accelerate the timeline during installation, ACS utilized on-machine M12 junction blocks, significantly reducing the startup time compared to traditional discrete wiring. Designed as an adaptable portable fuel filtration system, the entire fuel injector testing equipment setup was engineered to run the customer’s proprietary components alongside competitor products, establishing a highly flexible R&D platform.

The Outcome

The completed project successfully transitioned from a basic skid concept into a fully operational, integrated test cell enclosure that fits perfectly within the client’s existing lab footprint. By utilizing the existing building utilities, ACS eliminated the need for infrastructure overhauls, keeping the project highly efficient. The custom fuel injector testing equipment, featuring modern diesel conditioning filter systems, now allows the client to run automated routines where, based on the specific filters installed, the firing frequency, and the test type, the injectors are evaluated until they hit leakage or flow rate failure criteria.

The final filtration test results provide the customer with exact failure timelines, allowing them to optimize their product designs with unprecedented accuracy. Following successful Factory Acceptance Testing (FAT), commissioning, and Site Acceptance Testing (SAT) support, the client noted that they now possess “the most complex and capable test stand for our company internationally.” This robust fuel injector testing equipment ensures they can maintain a competitive edge in the on- and off-highway vehicle markets for years to come.

Key Features

• Fire-rated test cell stand designed to fit within existing test lab using existing building utilities
• Comprehensive safety systems for working fluids pressurized up to 40,000 psi
• Advanced portable fuel filtration system using ISO standard dust to evaluate filter effectiveness and injector failure times
• Comprehensive data acquisition measuring precise temperatures, pressures, and fluid flows
• On-machine M12 junction blocks to streamline and speed up facility startup
• Flexible platform for side-by-side benchmarking of proprietary and competitor products during a filtration test

ACS Services

• Design and build of fully integrated test stand and modular enclosure system
• Controls engineering, programming, and control panel build
• FAT, commissioning, SAT support