Once upon a time, we decided to raise the bar on test equipment…
After years of struggling to make a cobbled pile of test equipment perform, we decide to combine a long list of upgrades into a single test stand that could reliably run the routines needed to accurately characterize common PFI injectors. During development, we found that we had to change just about every important piece of the original test bench in order to perform useful engineering work. Early data collection processes for us took about eight hours of manually setting pressure, pulse width, number of shots, voltage and staring at the rig while the tests ran long enough to collect fluid in an open burette. After running a single condition long enough, a manual reading could be taken for each injector and transcribed into a separate data collection sheet to be reviewed later. This of course assumes that you didn’t have much evaporative loss while waiting for the fluid to collect during a long string of short pulses. Then, you dumped the fluid back into the tank, hoping to avoid spilling too much. After repeating this enough times over many hours, you finally had enough raw data to go back and process later. Don’t even get us started on cleaning and servicing the old bench.
We have turned this long, tedious process into a quick and easy test using our new bench. A break-in procedure has been integrated and gives the operator a chance to verify or adjust rail pressure before testing begins. A quick balance test can be done to compare injectors against each other in the set, yielding an easy to read report. The actual flow testing now happens quicker than it takes to run the break-in cycle. Data is automatically collected on the fly and written directly to a removable USB drive. This single data file is then uploaded to our cloud based app along with a few key pieces of information for processing.
Here’s the really cool part…
Getting the “flow rate” of an injector is actually quite easy. It’s just the slope of a straight line according to SAE J1832. The offset isn’t much harder to find as long as you understand the units. The tricky part comes when you try to go from generic SAE measurements into the complex OEM injector models used in modern ECUs. Not only do they operate at different pressures, they sometimes use interesting units for flow, offset and short pulse corrections where the injector is not yet linear. All of these are absolutely critical for the calibrator who wishes to get his airflow model correct at low flows like idle and cruising conditions.
Trying to pass emissions? Yeah, you better have good injector control before you start!
The good news is that we have done our homework for more than a decade helping the high performance aftermarket get these numbers, units, and data correct so that calibrators can just get on with the business of engine tuning rather than fumbling with injector flow in the dyno cell. Our online server allows the user to upload his data taken on the bench and get exact plug and play data that can be copied directly into a number of popular aftermarket ECU programming tools.
“But we already have numbers for XXX Injector, why run them on this?“
It’s a dirty little secret in the industry that not all fuel injectors of the same part number actually perform the same. Vehicle OEMs allow their injector suppliers to be as much as +/-6% on injector flow per part in order to keep productions costs low. This means that even if you have a set of OEM “high flow” injectors, not all of that set may me flowing what you think. (Our flow balance test will reveal this) Luckily, many of the better fuel injector suppliers in the performance aftermarket offer “flow matched” sets of injectors where the entire set is within just a percent or two of each other. Again, this is easily confirmed using our bench. Going a step further, an entire set of 8 injectors may all be within 1% of each other, but what is their exact flow rate, offset, and short pulse behavior? Using this bench, this data can be determined for the exact set of injectors on hand before installing them in an expensive race engine. This speeds up the calibrator when it’s time to sort out that initial tune on the dyno.
The data you get from our online processing tool will be the exact same format that we have been generating for clients over the last decade. Since our math is done by an actual calibration engineer who has had to use this data daily in OEM and emissions compliant applications, you can be assured that it’s done right. We have painstakingly reverse engineered the injector models used in many popular ECUs and done the math for you to turn your raw measurements into numbers that your ECU needs to operate properly. Thousands of users are already using these data sets in their applications today without issue. Now you can generate that same data quality on demand in minutes without the injectors leaving your shop!
More Good News
We make them here. you will not find our injector test bench on Alibaba. Domestically made products don’t get stuck on cargo ships. We build the benches right here in Michigan, with many of the same parts you’ll find under the hood of a reliable racecar. Our fuel pumps, filters, and regulators come from Deatschwerks in Oklahoma. You can clean and replace the filter easily using tools that you already have in your shop. If for some reason you need to replace a fluid line, you’ll find familiar -AN fittings everywhere inside. We focused on making something we would use ourselves and held our production specifications to the same standards. Everything from the construction of the bench to its simple operation and intuitive data output formatting stems from our decades of experience in actually doing the job. We’re not just an equipment manufacturer, we are experienced trainers who have helped thousands of other shops and calibrators up their game. This is just an extension of what we already do.
Pro Level Injector Bench
Features a laboratory grade flow meter, easily serviced 10 micron filter, USB data logging, a one year limited parts warranty.
Cost is $18,400.00 plus freight. This includes one year of single format data processing with our online server.
A 50% deposit is required upon ordering, with balance due before shipment.
Cloud Based Data Processing
We offer many output formats for our plug and play data. If your desired format is not already supported, contact us to see if it can be added.
Our online server processing is $450/yr for your first format, and $100/yr for each additional output format.
Each new bench includes one year of a single data output variant processing.
Although our bench has been validated to work with injectors ranging from 2-38 g/s flow rates, there are rare instances where we see some questionable results. If this happens, the first thing we always recommend is to re-run the test. It’s FREE because your data processing subscription is unlimited annual use.
If you Still have questionable data, Calibrated Success can perform a remote engineering review of your data set for $95 and go over the results with you. There are some injector designs that have proven to have limitations that are only found after close examination of the characterization data. In these cases, we can either help you develop a plan to proceed or let you make an informed decision if it’s best to choose another option.
“Data don’t lie. You’re the best“
Jon Banner, Fuel Injector Connection
“Dude, I am happy with my products but this is making me even more happy! It Looks Great!”
Brad Adair, Snake Eater Performance