Testing at k3 works – more than just a test

As experts on storage systems, we test and analyze complete systems, individual components and the interaction of these components. For this purpose, our team not only provides the required specialist know-how, but also years of experience – among other things with current and upcoming hybrid and SCR systems.

We are familiar with the legal requirements of the automotive industry worldwide. Within the scope of our flexible accreditation, however, we also search for innovative solutions, for example for your new developments. Here you can profit from our individual software solutions, innovative test equipment and our expertise on fuels and media.

At the end of a project, we not only supply you with reliable test results, but also advise you on solutions for identified weak points.

On request, we supervise for you the entire process chain, from the concept right up to series production.

Our spectrum of services comprises the testing on emissions, environmental simulations and functional inspections.

Emissions – close to the fuels

We operate test chambers especially prepared to the requirements of the automotive industry: In our Mini-SHEDs (Sealed Housing for Evaporative Determination), we inspect entire refueling systems for unwanted release of hydrocarbons. In our Micro-SHEDs, we are able to narrow down the search for faults to component level.

To achieve this, we expose your test samples over a certain time period to various pressure and temperature conditions or simulate the entire refueling process in a special procedure (ORVR - Onboard Refueling Vapor Recovery).

As specialists in refueling systems and components, we also determine the performance and aging of activated charcoal filters.

Environmental simulation – close to reality

In our laboratories, we are able to simulate all ambient conditions to which a system in a vehicle is exposed over its lifetime: temperature and pressure changes, vibrations and the confrontation with fuels and media. Motion simulation with temperature superimposition for SCR systems is one of our specialties.

The prototypes are inspected both in new condition and after aging. Here we look at other aspects as well as the measuring results: with our endoscopic procedures, we are able to keep an eye on the processes occurring inside the tank at all times – a clear advantage during troubleshooting.

As tank experts, we are familiar with both the increased demands on the tightness of hybrid systems and the sensitivity of SCR systems to cold temperatures.

Functional test – for vehicles and drivers

Independent of manufacturing companies, we inspect the functionality of refueling systems for vehicles and drivers.

Therefore, amongst other things we test the medium conveyance within the vehicle under various ambient conditions – also in interaction with contaminations or special fuels. To do this, we conduct pneumatic and hydraulic inspections and also put the electronics on the test bed.

For hybrid refueling systems, we also offer newly-developed testing procedures for the appropriate sensors.

During our functional tests relating to 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 that we are able to simulate a refueling process with all conventional pump nozzles and media available in the branch.

 

 

Software solutions – for smooth system communications

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.

The MAC2 team simulates malfunctions in the communication of the components, actuates individual components in order to test their function and performance spectrum and yet retains an overview of the optimum interaction in the overall system at all times.

In addition, our communication experts are glad to advise you on existing measuring systems and sensors.

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 – in accordance with the latest technological possibilities, and based on our years of experience.

We also make use of our years of expertise in analysis procedures for refueling systems and their components in order to design the appropriate test benches for your new developments.

Fuels – we get them all

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 procure the 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

For some time now, we have been considering how to provide further support in the development of hybrid refueling systems. These systems are characterized by an even higher tightness and frequently complex geometries. This generates new challenges both in design and in testing. As temperatures fluctuate, higher pressures result in the tight tanks than in conventional fuel tanks. Our pressure vacuum test benches, 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.