Case Study #1
High-pressure gasoline fuel systems have been dangerously prone to leak failure, mostly due to the vibration frequencies created by the fuel pump itself and by the high-torque engine. These engines run gasoline at 2200psi - a potential bomb if a leak should occur.
As a result of a presentation of a Banjo Fitting assembly incorporating Zero-Leak technology, the gasoline fuels engineering team at a Tier-One automotive supplier initiated a development program for a Banjo Fitting to meet their stringent requirements.
The Banjo Fitting assembly that resulted from this development program passed rigorous testing and is now being phased in on all high-pressure gasoline engines at two major automotive companies.
This picture shows the Banjo Fitting from the top of the bolt. These are made with an internal “Star-Drive” feature for the application of assembly torque. The profile of the complete assembly is thereby kept very compact. Space within the engine bay is very limited.
Note: Assembly torque may be applied by way of external or internal hexagon, Torx®, star-drive, etc., dependent upon customer needs.
Case Study #2
An automotive manufacturer needed a Banjo Fitting of unusual design to stop the frequent leaks it was experiencing with diesel fuel supply lines.
The company turned to Zero-Leak technology for the Banjo Fitting assembly to cure their assembly rework, warranty and in-house leakage. These lines are low pressure lines, but due to the vibration, leak failure had been a regular problem until they started using these multiple-seal Banjo Fittings.
The original design of the Banjo Fitting has been further developed to function in SAE J1926 and ISO 6149 type ports at pressures up to 6000psi working pressure.
The first high-volume use of this product is for a diesel fuel supply line. Cleanliness requirements for these lines are extremely demanding.
Components are assembled in a clean-room, de-greased and ultrasonic washed prior to shipment. Since 2002 when they begin being used, there has never been a reported leak.
This picture shows the special Banjo Fitting assembly for use in a standard ISO 6149 (M12) port. Bolts are shipped to the pump manufacturer for assembly to pumps (bolts are used for internal flushing of pumps). Pump/bolt assemblies are then shipped to the Automotive customer, where they are mounted on high-tech Diesel engines. Finally, hose-tube assemblies are attached to the bolts to create a totally Zero-Leak fuel supply system.