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Recognize details. Optimize combustion. Increase power. Optical quality inspection for fuel injection

Maximum precision in quality control - Efficient & sustainable fuel injection

The quality of fuel atomization and injection is crucial for the efficiency, performance and environmental friendliness of combustion engines. An uneven spray pattern, faulty fuel distribution or inconsistent droplet sizes can significantly impair combustion efficiency and increase pollutant emissions.

With LaVision’s high-precision optical measurement systems, you can ensure that your fuel injection systems meet the highest requirements. Whether for diesel injection, gasoline direct injection or alternative fuels such as hydrogen and ammonia – our modular systems enable complete quality control for all types of fuel atomization and injection technologies.

The right partner for your product quality

Leading automotive manufacturers (OEMs), system suppliers and engine developers worldwide rely on our measurement technologies for monitoring, optimization and quality assurance in industrial production. By fully integrating our measurement systems with the powerful DaVis Quality Control software, we support our partners from research and development (R&D) to quality management (QC) and inline quality measurement in ongoing production.

Optimum fuel distribution – maximum combustion efficiency with minimum emissions

Reduction of power losses & fuel consumption – Better mixture formation for more efficient engines
Controlled particle & droplet size distribution – Uniform injection without loss of power
Automated quality assurance – reproducible & objective measurement results for the highest product standards
LaVision SprayMaster system testing fuel sprays for droplet distribution and spray pattern analysis

SprayMaster inspex - Comprehensive quality control for fuel injections

Thanks to innovative optical measurement technology, our system recognizes all relevant parameters from the injection process and provides comprehensive support for quality control and detailed documentation.
This ensures consistent quality in series production.

The SprayMaster inspex Base Frame, as the basic equipment concept, forms the central platform of the system. With a universal holder, injection systems, injection nozzles and other applicators of various shapes and sizes can be securely positioned. Measurements are made using backlit imaging, light sectioning technology and shadowgraph analysis, which enable complete characterization of the spraying process. The system is specifically designed for use in research laboratories and product development environments. Automatic digital measurement data recording with DaVis software.

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The SprayMaster enables high-resolution analysis of all relevant parameters in fuel injection systems. This includes the precise determination of the spray cone angle and the main axis direction for an exact evaluation of the spray geometry. The system also records the spray shape and spread over the entire injection process and provides valuable data on cone stability and spray density distribution. By recording dynamic spray patterns in real time, injection processes can be comprehensively characterized, validated and optimized in terms of atomization efficiency, combustion yield and emission behavior.

Axial view of fuel spray plume illuminated by radial light sheet for optical spray analysis
  • Early fault detection: Prevents loss of performance & increases efficiency
  • Automated & reproducible measurements for consistently high quality
  • Flexible integration into production processes: Can be used inline, atline, online & offline
Optical spray analysis capturing droplet distribution and spray pattern for research and industrial applications

ParticleMaster inspex - Precise droplet & particle analysis for fuel atomization

The ParticleMaster inspex provides a detailed analysis of droplet size & particle distribution in fuel injection systems. Thanks to LED-based measurement technology, it ensures uniform injection & optimum combustion efficiency.
The ParticleMaster inspex uses LED-based shadowgraphy technology with high-resolution droplet recording. The light source and sample are placed outside the spray area so that electrical components do not come into contact with the spray. The ultra-fast LED light source freezes the droplet movement for inline analysis. The high-resolution camera system in the sample precisely records the droplet size, speed and shape. The computer-based evaluation of the recorded images ensures operator-independent, reproducible results in the shortest possible time. The compact design allows easy integration into the quality assurance and production line.
LaVision ParticleMaster inspex system analyzing fuel spray particles for droplet size and distribution
  • Particle concentration:
    Number and mass concentration within the spray jet
  • Particle homogeneity:
    Shape, density and uniformity across the spray cross-section
  • Particle size distribution spectrum:
    Detection of minimum to maximum diameters between 10 – 2,500 µm depending on equipment model and application
  • Spray density profiles:
    Distribution of the particle concentration across the width and depth of the spray
  • Particle velocity (optional for combined measurement):
    Velocity and dynamic distribution of individual particle droplets. These measured variables enable precise quality control and process optimization in product development.
Optical analysis of injection system showing droplet size, numbers, and cumulative distribution in a graphical display
Optical analysis of fuel injection systems for precision quality control in engines
  • Highest precision – Scientifically sound measuring methods for exact droplet and particle analysis
  • Digital & reproducible results – comparability with reference values for consistent quality assurance
  • Automated data acquisition & evaluation – Efficient analysis with powerful DaVis software

  • Flexible use – can be used inline, atline, online & offline

Intelligent quality
control with the LaVision Quality Control software

The LaVision Quality Control software is the central element for efficient, automated and seamless quality testing of a wide range of injection processes. It enables seamless data acquisition, analysis and documentation of all relevant spray parameters and ensures consistent and standard-compliant quality assurance – from the first test through to series production. Full integration with the SprayMaster inspex and ParticleMaster inspex systems allows test sequences to be automated, results to be compared precisely and all relevant data to be recorded in real time. The software offers a user-friendly interface, customizable test criteria and automatic report generation for efficient and transparent quality assurance – from the first test to series production.

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Main functions & advantages

  • Automated data acquisition and real-time analysis – fault detection during the testing process
  • Comparison with reference values and quality standards – Immediate validation of the injection parameters
  • Standard-compliant documentation – complete traceability of all measured values for audits and certifications
  • Connection to production control systems (ERP & QMS) – Integration into existing automation solutions
  • Visual evaluation with AI-supported algorithms – detection of the smallest deviations in spray pattern and particle distribution
  • Consistent and objective measurements – Eliminates human error and ensures reliable quality assurance
  • Increased efficiency through automated processes – faster test cycles and improved production planning
  • Reduction of rejects and production downtime – Early detection of sources of error
  • Improved traceability and compliance – Automatic logging for full traceability
  • Simple operation and intuitive user interface – Reduces training requirements for employees
  • Modularly expandable and extremely future-proof – Adaptable to new requirements & future fuel technologies
  • Automotive industry: Quality testing of injection nozzles and fuel systems in engines
  • Aviation: Control of fuel injection systems for engines
  • Alternative fuels: Optimizing the injection quality of hydrogen and ammonia

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Maximum efficiency in quality control

Our practical experience: Our integrated QC systems significantly reduce the inspection time and reduce the number of quality returns with regard to painting and coating quality to zero.

Fully automated quality assurance on a new level:

  • Faster test cycles thanks to automated data acquisition
  • Seamless documentation for maximum traceability
  • Error minimization & process reliability for optimized production

Optical analysis. Reliable data.
Best possible combustion.

Optical measurement systems from LaVision enable the precise analysis and evaluation of spray patterns, droplet sizes and fuel distribution – directly in the development or quality process. Our powerful evaluation software ensures reproducible results, transparent comparisons and well-founded decisions. This increases your process reliability, reduces material losses and ensures consistently high product quality.

Ensure the quality of your injection systems
Advance innovation today
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