Testing at k3 works - emissions, environmental simulations and functional tests

Our expertise is based on many years of experience in testing conventional refueling systems and their components, hybrid and SCR systems.

With our flexible accreditation, we support you in testing your refueling systems and carry out emission measurements, environmental simulations and functional tests for you. 

We use innovative test benches and individual software solutions tailored to the customer. 

Emission measurement for refueling systems

We have test rigs and test chambers specially tailored to the needs of the automotive industry: In our Mini-SHEDs (Sealed Housing for Evaporative Determination) we carry out purity analyzes or permeation measurements and check complete refueling systems for undesired releases of hydrocarbons and vapors.

In addition, with our Micro-SHEDs we can limit troubleshooting at component level and expose your test sample to different pressure and temperature conditions, for example in climatic chambers, over a certain period of time, or simulate the entire refueling process (ORVR - Onboard Refueling Vapor Recovery).

In connection with this, as a fully equipped fuel laboratory for refueling systems and components, we also offer the necessary legally compliant aging and conditioning of activated carbon filters.


Environmental simulation for refueling systems - from temperature changes to vibration tests

In our laboratories, we can simulate all the environmental conditions to which a system in a vehicle is exposed over its lifetime: temperature fluctuations and pressure changes, vibration and shock tests and compatibility with different kinds of media: fuels, oils, lubricants, detergents and AdBlue.

In the event of a fault, our burst pressure test bench provides in-depth knowledge of the maximum pressure load on the refueling system.

One of our outstanding competencies is motion simulation with temperature overlay tests for SCR systems.


Functional test of refueling systems

We inspect the functionality of refueling systems for the vehicles and drivers - regardless of the manufacturing companies.

For example, we test the medium conveyance through fuel pumps and other hydraulic components in the vehicle under various environmental conditions, e.g. in continuous operation, in hot and cold delivery as well as in conjunction with impurities or special fuels. 

For hybrid refueling systems, we also offer you newly developed testing procedures for sensor technology.

During our functional tests relating to the driver control, we inspect amongst other things the sensors for the fuel gauge and acoustic stress caused by the refueling system. Our laboratories are also equipped in such a way that we can simulate a refueling process with all conventional fuel nozzles and media available in the branch.

Software solutions – for a smooth system communication with your refueling systems

A refueling system only runs without malfunctions if the software for each individual component is optimally aligned with the others. In order to check this system communication, we standardize and develop special test equipment and the associated software.

For such tasks, we at k3 works have employed true professionals: the MAC2 (Measurement and Application Competence Center) team – our communications experts for your refueling systems.

Test benches – individually designed

At k3 works, the testing environments are optimally aligned to your requirements. To achieve this, we build and program our electronically-controlled test beds ourselves - from the pressure change test to the slosh test to the temperature change test, we test your refueling system according to the latest technical possibilities and on the basis of our many years of experience.

Fuels - we test all fuel types and special additives

The fuel used in testing procedures is of significance, as it allows us to make reliable statements on the functionality and material resistance of refueling systems and their individual components.

For the inspections at k3 works, we  - in addition to certified fuels such as CARB Phase III, EPA TIER III or EURO 6 E10 - procure different fuel types for all refueling systems, special fuels with special additives and fuels in qualities specific to the respective countries. On request, we can also have particularly aggressive fuels mixed at our suppliers according to your specifications.

We also store conventional media used for other systems such as AdBlue or windscreen washer tanks.

Our specially-trained employees are familiar with the standards and are experienced in the handling of hazardous substances. They work using explosion protection and hydrocarbon monitoring protection in our laboratories, in a safe testing environment.

Hybrid tanks – demanding systems for the future of mobility

Hybrid refueling systems are characterized by an even higher level of tightness and a geometry that is often more complex due to higher pressure requirements.

This generates new challenges both in design and in testing. Our pressure vacuum test beds, but also our test tanks for sensors, have been dimensioned appropriately.

Another frequently-observed effect is the deformation of the tanks, resulting from the pressure and geometry. Through appropriate measurements prior to, during and after the tests, we are able to record deformations accurately and correlate the results with the superimposed environmental simulation. Here you receive important guidelines on the optimization of your systems and for the dimensioning of the installation space.

One highlight of our work is of course the pressure-superimposed measurement of the height-volume characteristic curve with simultaneous recording of the tank deformation – for security regarding the range indicator.