Horizontal Flash Measuring Machine IWS-200: Precision Quality Solution for New Energy Injector Nozzle Hole Diameter & Cone Angle Measurement

With the rapid growth of the new energy vehicle industry, the injector—as a core component of the fuel injection system—directly impacts engine combustion efficiency, emission performance, and overall vehicle power output. The micro-hole diameter and cone angle precision of injector nozzles are critical parameters that determine fuel atomization quality and injection direction. However, these parts often feature irregular tapers, leaving traditional inspection methods trapped in a dilemma between "clamping deformation" and "positioning failure"—rigid fixturing easily distorts the workpiece, while no fixturing makes precise positioning nearly impossible. The Horizontal Flash Measuring Machine IWS-200, developed by SIG, delivers an efficient and accurate solution to this industry-wide challenge.

I. Inspection Challenges of New Energy Injector Nozzles

New energy vehicle injector nozzles present the following distinctive characteristics:

• Complex Geometry: The nozzle tip features a precision taper, with micro-hole diameters typically in the millimeter or even micrometer range—beyond the capability of traditional contact instruments like calipers and micrometers.
• Precision Materials: Nozzles are typically made of high-hardness metals with extremely high surface finish requirements. Contact measurement risks scratching the component surface.
• High-Volume Batch Inspection: The fast-paced production lines of new energy vehicles demand exceptionally high inspection efficiency. Traditional sampling inspection can no longer meet the "zero-defect" mass production target.

For tapered, irregularly shaped injector nozzles, conventional inspection methods face an awkward reality: rigid fixturing deforms the workpiece and distorts measurement results; without fixturing, the workpiece cannot be stably positioned, and measurement repeatability becomes unattainable. This contradiction has long plagued quality control in new energy injector nozzle manufacturing.

II. Core Technological Advantages of the SIG Horizontal Flash Measuring Machine

The SIG Horizontal Flash Measuring Machine IWS-200 is specifically engineered to address these challenges.

1. Dual Telecentric Optical System – Eliminating Perspective Error

The horizontal flash measuring machine is equipped with a dual telecentric lens that achieves parallel chief rays on both the object and image sides, completely eliminating the "near-large, far-small" perspective error inherent in conventional lenses. This ensures consistent magnification regardless of where the workpiece is placed within the field of view. For tapered, irregular parts like injector nozzles, this means stable and reliable image data can be obtained without precise positioning—simply place the part and measure.

2. No Fixturing Required – Direct Placement

To overcome the "clamping deforms, no clamping loses positioning" dilemma, the horizontal flash measuring machine employs non-contact optical measurement. Workpieces are placed directly on the measurement platform. The software automatically matches the workpiece template, eliminating the need for additional fixtures and fundamentally preventing clamping-induced measurement errors.

3. Sub-Pixel Image Algorithm – Micron-Level Accuracy

The SIG flash measuring machine utilizes sub-pixel edge detection algorithms—including grayscale gradient fitting and edge interpolation—to enhance measurement resolution to the 0.1-pixel level. Combined with high-magnification dual telecentric optics, it achieves ±1μm repeatable measurement accuracy, fully meeting the precision requirements for new energy injector nozzle micro-hole diameter and cone angle inspection.

4. One-Click Flash Measurement – High-Volume Batch Efficiency

Operators simply place workpieces on the measurement platform, click once, and the device automatically completes all dimensional measurements within seconds. A single image capture can measure dozens or even hundreds of parameters. The system supports batch placement with automatic part recognition and individual measurement—representing a revolutionary leap in inspection efficiency for high-volume new energy injector nozzle full inspection.

III. What Can Be Measured?

The SIG Horizontal Flash Measuring Machine IWS-200 precisely measures the following critical parameters for new energy injector nozzles:

• Micro-Hole Diameter: The orifice diameter of the injector nozzle, which directly determines fuel injection volume and atomization performance.
• Cone Angle Precision: The taper angle at the nozzle tip, which affects fuel injection direction and dispersion range.
• Hole Distribution & Position Tolerance: Relative positional accuracy among multiple orifices in multi-hole injectors.
• Length, Width, Spacing: Linear dimensions of various injector nozzle features.
• Geometric Tolerances: Including concentricity, parallelism, profile tolerance, and more.

All measurement data can be automatically exported to statistical analysis reports, supporting SPC data management and integration with MES/ERP systems for quality traceability and process optimization.

IV. Problems Solved

Problem 1: Measurement Distortion from Clamping Deformation

• Traditional Approach: Injector nozzles with irregular tapers are easily deformed by rigid fixturing, resulting in measurements that do not reflect true dimensions.
• SIG Solution: Non-contact measurement with direct workpiece placement—no fixturing required, eliminating clamping deformation at the source.

Problem 2: Poor Repeatability Due to Positioning Failure

• Traditional Approach: Without fixturing, workpieces cannot be stably positioned; varying placement leads to inconsistent data.
• SIG Solution: The dual telecentric lens ensures constant magnification regardless of placement, and the software automatically matches templates for precise identification and measurement from any position.

Problem 3: "Can't See, Can't Measure" Micro-Holes and Cone Angles

• Traditional Approach: Micro-hole diameters are too small and taper angles too complex for conventional measuring tools to measure directly.
• SIG Solution: High-magnification dual telecentric optics combined with sub-pixel algorithms clearly image micron-scale features and deliver accurate aperture and cone angle data.

Problem 4: Low Batch Inspection Efficiency

• Traditional Approach: Manual part-by-part measurement is slow, error-prone, and limited to sampling inspection with high escape risk.
• SIG Solution: One-click flash measurement—seconds per part—with batch placement and automatic recognition, making 100% full inspection a practical reality.

V. Application Value

In the high-volume precision quality inspection of new energy injector nozzles, the SIG Horizontal Flash Measuring Machine IWS-200 leverages its core advantages—non-contact measurement, no fixturing required, and one-click flash measurement—to perfectly resolve the long-standing dilemma between "clamping deformation" and "positioning failure." It not only delivers precise measurement of micro-hole diameters, cone angles, and other critical parameters but also boosts inspection efficiency by 10–20 times-, empowering manufacturers to transition from sampling inspection to full inspection.

For new energy vehicle component manufacturers pursuing "zero-defect" mass production, the SIG Horizontal Flash Measuring Machine IWS-200 is an indispensable precision quality inspection solution.

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