Case Study Title: Endurance Testing System for High-Pressure Gaseous Injectors
Client Type: Private, green-technology firm
Scope and Capabilities:
ATA designed, built, and commissioned a custom endurance test system to validate the performance of up to 18 high-pressure CNG injectors. The system was developed to simulate real-world thermal and pressure cycling, with precise control over flow, temperature, and actuation parameters. It offered a programmable cycle rate of up to 100 Hz with a nominal pulse width of 1.5 ms (fully adjustable), and operated at working pressures up to 400 bar with components rated to 700 bar. The temperature range was controlled between 0°C and 40°C, enabling stable operating conditions throughout testing. Flow capability included up to 100 g/s per individual injector, with a system average of 45 g/s, and support for parallel injection of up to three injectors simultaneously.
Key Features:
The system featured an 18-station injector fixture bay with manual clamping and isolation, supported by a CNG gas booster with PID-regulated supply and backpressure control. An integrated receiver tank and thermal control circuit ensured stable operating conditions, while mass flow measurement and high-frequency data logging provided precise performance tracking. The entire process was fully automated through ATA’s Engine Component Test Software (ECTS), enabling consistent test execution and reliable data collection.
Deliverables:
The project delivered a fully integrated, turnkey test system designed for injector endurance and performance evaluation. It included custom test scripts along with both remote support and on-site commissioning to ensure smooth operation. The system provided high-resolution, synchronized data across all test parameters, while its flexible configuration allowed compatibility with a range of different injector models.
