Combustion Engine & EV Components tested Under Extreme Conditions
Common rail systems operate at 3000 bar during injection events. Pump heads cycle millions of times between idle and redline. Injection lines must withstand pressure spikes that destroy inferior materials in weeks. Our automotive pressure testing systems validate these components before they reach your production line. We don’t build catalog equipment. Each test rig is engineered around your component geometry, pressure requirements, and test media – whether oil, brake fluid, coolant, or compressed air.
From 20 Bar Cooling Circuits to 6000 Bar Impulse Testing
Automotive components span enormous pressure ranges. Air conditioning lines operate at 20 bar. Common rails reach 3000 bar. Our 6000 bar impulse test stand handles the most demanding endurance validation using Bosch Rexroth hydraulics and Siemens PLC control. We test cooling manifolds, battery and ADAS cold plates up to 70 bar burst pressure. Pressure cycle testing runs at 20 bar with PG25 coolant, using wave and square pressure curves at frequencies up to 2 Hz. This simulates real thermal cycling in electric vehicle battery cooling systems.
Autofrettage for Fuel System Durability
Common rails, pump heads, and injection lines require autofrettage to achieve target fatigue life. Our autofrettage systems reach 15,000 bar using hydraulic pressure intensifiers designed in Nordhausen, Germany. The process applies controlled overpressure that creates beneficial residual stress patterns in the component walls. This extends fatigue life up to 30% compared to non-autofrettaged parts — critical for components that must survive 300,000 kilometers of pressure cycling.
Specialized Testing for Complex Geometries
Large components like accumulators and composite pressure vessels require different approaches. Our dual-chamber test stands handle components too large for standard fixtures, generating pressure loads up to 800 bar at frequencies reaching 10 Hz using P+P flex pressure intensifiers.
For composite overwrapped pressure vessels (COPVs), we engineer autofrettage procedures up to 1050 bar using filtered water. The integrated tilting device handles heavy vessels while steel safety chambers contain potential ruptures during burst testing. Hose testing presents unique challenges as components change shape under pressure. Our hose test bench includes integrated laser measurement systems that track dimensional changes and torsion in real-time while quick-connect fittings enable rapid component changeover.
Beyond Standard Automotive Applications
Racing applications push components beyond normal automotive limits. Our burst test rigs validate prototype designs using hydraulic, pneumatic, or pump-driven pressure intensifiers up to 15,000 bar. We also handle auxiliary systems: nitrogen charging units for large accumulator systems and compressed air boosters that increase workshop air from 3 bar to 50 bar for specialized tooling. Each system includes complete data acquisition, recipe management through Siemens HMI interfaces, and full traceability for component certification. Our engineering team in Thuringia works directly with your R&D departments to solve specific testing challenges — not sell standard equipment.
6000 bar impulse test stand
Developed in cooperation with Maximator, this 6000 bar pressure impulse test stand combines robust high-pressure technology with advanced control and hydraulic systems. Equipped with a hydraulic pressure intensifier, a Bosch Rexroth hydraulic unit, and a Siemens PLC, it ensures precise, repeatable pressure cycling for demanding endurance and fatigue tests. Contact us to learn more.
Large Components | Burst- and Pressure Cycle Test Rig
The test stand has two large chambers in which individual burst pressure and pressure cycle tests can be executed. Our state-of-the-art P+P flex pressure intensifier covers large components, such as accumulators, and generates pressure load changes of up to 800 bar with a frequency of up to 10 Hz.
Pipe and Hose Test Bench
Hoses, pipes and pipe connections must reliably withstand operational pressures and predefined pressures during testing. To prove the component and material quality, they are exposed to pressure, sometimes to the point of failure or bursting.
High-Pressure Burst Test Stand
Components are exposed to extremely high pressures during operation and must be tested for quality and material fatigue. Our high-pressure test bench for burst pressure tests up to 15,000 bar can put any component to the test.
Autofrettage for R&D and Prototypes
The autofrettage system is ideal for research and development and prototype manufacturing. The rig enables manufacturers to mount different components with a flexible fixture system. Therefore a high variety of components, designs and prototypes can be autofretted on the system.
Autofrettage for (Diesel) Injection Lines
High-pressure lines such as diesel injection lines (common rails) are autofrettaged for continuous use with pulsating pressure in series production. By applying the autofrettage process component service life can be increased by up to 30%.
Common Rail Serial Production Autofrettage
This state-of-the-art autofrettage system is the perfect solution for the serial production of common rails. Our flagship system is utilized by manufacturers around to world. It enables improvement of the fatigue strength of common rails, injection lines and other components.
Multipurpose Autofrettage
Our multipurpose autofrettage system is ideal for research and development. In addition, is also well equipped for smaller serial production lines up to 13000 bar.
Burst and Pressure Cycle Test Stand
A state-of-the-art dual chamber test rig for simultaneous burst and pressure pulsation testing. The rig enables testing flexibility in your lab. A media heating and cooling unit can be installed to cover an even wider range of test requirements.
Double Chamber Test Rig for Burst and Pressure Cycle Tests of Coolant Hoses
Our flagship double-chamber test bench can test up to 10 DUTs (e.g. coolant hoses) simultaneously. In addition, we enable ambient and fluid temperatures of -60°C to 180°C. Further, our test rig is equipped with separate 3x media circuits to enable testing with oil, water and water glycol emulsion for dynamic pressure cycle and burst testing up to 800 bar.
Autofrettage
Common Rails
Even as e-mobility rises and investments in new components and technologies grow, the combustion engine remains an integral part of the future. We offer state-of-the-art test benches for conducting autofrettage processes and testing common rails, pump heads, and injection lines for research and development, as well as series production. In addition, we support customers with bursting pressure, leakage and pulse pressure test benches for various components.
Contact Us
Our experienced technical sales team will help you implement your project and find a solution tailored to your specifications and requirements. We are represented internationally and can support you and your company worldwide. Our team has completed hundreds of projects many of which involved supporting test facilities with identical equipment. P+P Maschinenbau is your internationally trusted partner.