Measurement & Testing Systems
MagHyst® for Fuel Injectors
Fuel injectors for gasoline, diesel, and hydrogen engines, as well as for industrial gas applications, represent the high-end class of electromagnetic valves. Hardly any other component combines such demanding requirements in terms of dynamics, precision, reliability, and reproducibility.
The primary function of a fuel injector is the highly accurate metering of the injected medium. Even the slightest deviations in the moving components can influence the injection behavior and, consequently, the performance of the overall system. Accordingly, the requirements for design, manufacturing, calibration, and quality assurance are extremely high.
Typical armature strokes of modern fuel injectors are in the range of only a few tens of micrometers, while switching times can be as short as a few tens of microseconds. This results in exceptionally high demands on manufacturing accuracy, assembly quality, and the adjustment of critical parameters with tolerances in the micrometer range.
In addition, fuel injectors require extensive pre-production investigations, validation processes, and continuous monitoring of production quality.
With MagHyst® technology, the injector’s excitation coil is transformed into an intelligent sensor, enabling fully sensorless monitoring of actuator behavior. This approach allows a comprehensive, non-destructive analysis of:
- Armature position and dynamic switching behavior
- Force–stroke characteristics of the actuator
- Magnetic material properties and coil integrity
- Performance variations as a function of temperature and pressure
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During the development phase, highly precise measurement data supports the validation of simulation models and enables fast, reliable design iterations. In production, inline testing ensures the early detection of assembly deviations such as air gap variations, mechanical friction, or winding defects. For lifetime evaluation, long-term testing provides valuable insights into wear mechanisms and performance changes during operation.
At MagTronX GmbH, this technology is applied in demanding injector projects, from compact electromagnets for diesel injection systems with strict installation space constraints to high-performance actuators for hydrogen direct injection at pressures of up to 350 bar.
For further information regarding measurement solutions or project collaborations, please feel free to contact us.
Through the highly precise measurement and control of electrical parameters, MagHyst® enables both the reliable detection of hidden faults within the electromagnetic mechanical system and highly accurate sensorless displacement measurement of the armature.
One particularly important field of application is the adjustment of the armature base position, which represents an essential manufacturing step for many fuel injectors. Even minimal deviations in this adjustment can significantly affect the injection quantity and the dynamic behavior of the valve.
The inductive sensorless measurement methods integrated into MagHyst® offer decisive advantages over mechanical or optical measurement techniques. Particularly in fuel injectors, direct displacement measurements are often only possible with considerable technical effort, since the moving components are located within a completely sealed assembly.
Furthermore, the required measurement accuracy in the micrometer range, combined with the high production volumes of serial manufacturing, makes the use of conventional measurement technology particularly challenging.
With MagHyst®, the magnetic coil of the fuel injector itself assumes the function of the sensor. As a result, the armature position can be determined directly from the electromagnetic properties of the system, without additional sensors, without modifications to the design, and without affecting the production process.
Standard MagHyst® measurement systems are capable of measuring and evaluating armature positions with an accuracy down to approximately 1 µm.
In addition to conventional fuel injectors, there are also specialized low-volume applications in which the electromagnetic and hydraulic functional units are assembled directly within the engine cylinder head during the assembly process.
Particularly in these highly integrated designs, MagHyst® enables the reliable prevention of assembly errors as well as the precise adjustment of the assembly directly during the manufacturing process. As a result, scrap rates, rework, and testing effort can be significantly reduced.
Typical Applications of MagHyst® for Fuel Injectors
- Development and prototype validation
- Pre-series and series production approval
- End-of-Line (EOL) testing
- Process monitoring in manufacturing
- Sensorless armature displacement measurement
- Adjustment of the armature base position
- Detection of friction, sticking, and wear
- Verification of spring forces and air gaps
- Detection of magnetic and electrical deviations
- Prevention of assembly errors
- Lifetime and endurance testing
By combining highly precise diagnostics, sensorless displacement measurement, and comprehensive fault analysis, MagHyst® represents a powerful tool for the development, manufacturing, and quality assurance of modern fuel injectors. The technology provides an unprecedented insight into the dynamic behavior of electromagnetic fuel injection systems and establishes the foundation for maximum precision, process reliability, and product quality.