Research & Development

Smarter valves. Lower emissions.

Research & Development

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Smarter valves. Lower emissions.

Our Approach

Innovation drives everything we do. Our dedicated Research & Development team is focused on advancing engine air technologies that meet the growing demands of performance, efficiency and environmental responsibility.

By combining deep industry expertise with cutting-edge tools, we develop components that help manufacturers achieve reliability, compliance and long-term value.

From concept to prototype and final validation, our R&D process is built on collaboration, precision and continuous improvement. Using advanced simulation, testing and materials research, we push the boundaries of what’s possible in air management systems.

This commitment ensures that every solution we deliver not only meets today’s standards but anticipates the challenges of tomorrow’s transport industry.

R&D Capabilities

Dynamic suite of advanced testing capabilities

Hot Testing

GT has 1 kiln with a 350L capacity. The kiln is capable of both static and cyclic test between Ambient temp and 700°C. Fixtures can be mounted internally to support test pieces and electronic motors can be connected to linkages behind the kiln to operate valves while inside.

Cyclic Corrosion

GT has 1 cyclic corrosion chamber with a 1000L capacity. The chamber is capable of all conventional salt spray / salt fog testing with up to 98% relative humidity, air purge cycles and from ambient to 70°C dry heat. Valves can be mounted/hung in the chamber in the correct orientation throughout the test. Pneumatic lines or electrical cables can be ran inside the chamber to operate valves during corrosion cycles.

Leakage Testing

GT has a custom-built leakage rig comprising of 3 different flow meters spanning a wide range of values. Flow meter 1 is 0 – 2000 l/min (0 Decimal Places) . Flow meter 2 is 0 – 60 l/min (2 Decimal Places). Flow meter 3 is 0 – 200 cc/min (2 Decimal Places). All flow meters have a max inlet pressure of 2 bar. Each valve has a purposely designed set of sealing flanges allowing the rigs to connect easily to test.

Hysteresis

GT has a custom-built Hysteresis/Response time & leakage test rig. This allows GT to perform the Hysteresis or Response time on both valve assemblies and Actuators whilst also performing a leak test on the actuator. All testing solely on actuators are done using the same fixtures as endurance testing for comparable data. All data is logged using CAN (.MDF format) into Vector CANalyzer software and can then be reviewed in Vector vSignalyzer.

Thermal Endurance

GT has 9 total test cells. Each cell contains a mobile trolley that contains all equipment need to perform any testing. Each trolley is comprised of a custom control panel, blower and ceramic element heater. Up to 4 valves can be mounted to each trolley (size and test type dependant). The heaters are capable of up to 900°C. Temperature cycling profiles can be written using software and loaded into the panels (Example below).

Environ. Chamber

GT has one Environmental Chamber with a 335L capacity. The chamber is capable of static temperature testing at -40°C - 180°C as well as cyclic testing between the two values. (Max change rate 2.5K/min). Humidity testing can also be performed separately or in parallel with temperature with 0-100% Relative humidity. Pneumatic lines or electrical cables can be run inside the chamber to operate valves during testing.

Dirt Spray

GT has 1 dirt spray chamber with an 800L capacity. The chamber can be filled with a wide range of media wet or dry and sprayed in various patterns with different nozzles. Pressures and pump speeds can be adjusted manually, and spraying can be semi-automated using an internal mount for the nozzle.

Cold Testing

GT has 1 Freezer with a 700L capacity and a temperature range of 0°C – -85°C. The freezer has space for a large number of valves or actuator fixtures for low temperature testing. Pneumatic lines or electrical cables can be run inside the chamber to operate valves during testing.

Fume Chamber

GT has 1 Fume chamber with a 650L capacity. The fume chamber has space for full valve assemblies or individual components depending on the test requirements. The chamber has water & gas lines as well as extraction from the building.

Actuator Thermal Endurance

GT has 2 Binder Ovens with 400L capacity each and max temperatures of 300°C. Each oven can hold 6 racks of actuators in custom fixtures totaling 48 × 35mm actuators, 36 × 50mm actuators or a mixture of both. Oven 1 is fully controlled via PLC with hour-by- hour settings for temperature and actuation frequency. Oven 2 is for static temperatures only with plans to be integrated into the PLC in 2023.

Prototyping Capabilities

- Machining capability to produce rapid prototypes.
- Dedicated prototype area for controlled valve assembly.
- All prototypes built have full traceability for dimensional reports & leakage performance.
- Thermal testing performed to verify prototypes prior to customer delivery.
- All parts are subjected to complete inspection, tear-down, measurements and report generation post testing.
- Instrumented samples to support diagnostics in test.

Your Project. Our Expertise. Let’s Talk.

Key Contact:
Chris Hutler
Chris.Hutler@gt-emissions.com

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