Details

The Combined Control Unit (CCU) Test Rig is a cutting-edge, fully automated testing system designed to evaluate servo hydraulic actuator performance for MI8 helicopters and fighter aircraft. It performs essential tests such as frequency response analysis, dynamic load simulation, and cyclic performance checks to ensure the reliability and safety of aviation components. Specifically built to handle servo units like KAY-30B and PA-60B, the system integrates advanced data acquisition (DAS), custom report generation, and a 17-inch touch-screen interface for streamlined operations. With stainless steel hydraulic components, precise load measurement, and both automatic and manual modes, it is a vital tool for aerospace manufacturers, military maintenance teams, and hydraulic system validation across the aviation sector.

The Combined Control Unit (CCU) Test Rig is an advanced, industrial-grade platform designed for servo hydraulic actuator testing. Developed to meet the stringent needs of the aviation, aerospace, and defense industries, it ensures comprehensive performance verification of components used in helicopters and fighter aircraft. The rig is capable of conducting various essential tests, such as frequency response analysis, dynamic load simulation, and cyclic tests, all automated with an integrated data acquisition system (DAS).

The system supports both automatic and manual operation modes, allowing operators to customize test sequences and generate reports without extensive manual intervention. This hydraulic testing rig is an invaluable tool for ensuring the safety and performance of flight control systems and other aviation-grade components.

Applications
This test rig is ideal for:
  - Testing and adjusting Combined Control Units (CCU) in MI8 helicopters and other aircraft.
  - Conducting acceptance, control, and periodic testing of servo units such as KAY-30B and PA-60B.
  - Validating hydraulic actuators and servo control systems for aviation and defense.
  - Simulating dynamic load conditions and performing critical performance assessments of hydraulic system components.

The system is tailored for aviation manufacturers, military maintenance facilities, and aerospace component engineers who require precise, reliable test results.

Key Features and Benefits
Combined Control Unit (CCU) Test Rig for Aviation and Defense Applications
The test rig is designed to enhance operational efficiency and reduce downtime. The core features include:

  - Ease of Operation:
    The rig is equipped with touch-screen controls, step-by-step automated test protocols, and minimal manual input requirements.
 
  - Safety and Reliability:
    Built-in safety features continuously monitor and protect critical test components. The system automatically checks parameters to ensure safe operating ranges.

  - Advanced Data Handling:
    Test data is recorded, analyzed, and stored with custom report generation capabilities. Integration with maintenance management systems is fully supported.

  - Flexibility and Scalability:
    Operators can perform manual override testing for non-standard test requirements. The system supports custom test schedules, test data formats, and reporting structures.

Technical Specifications
This hydraulic actuator testing rig is designed with precision-engineered components to ensure optimal
performance.

The system uses hydraulic oil (AMR-10) as the working fluid, with a maximum pressure capability of 80 Kg/cm2. In functional mode, the operating pressure ranges between 42 and 73 Kg/cm2, and the system can handle fluid temperatures up to 80°C.

For leakage testing, the rig can measure flows up to 2000 cc, with a nitrogen accumulator pressure maintained at 30 ± 2 Kg/cm2. A 10 kW, 3-phase electric motor with 1460 RPM drives the hydraulic system. The tubing and other critical components are made from stainless steel (SS 316) to ensure corrosion resistance and durability.

The cooling system utilizes chilled water, while heating is achieved through the hydraulic pump's relief flow.
The hydraulic contamination level is maintained according to NAS 1638 standards.

System Components and Layout
The system comprises four main components: the hydraulic system, mechanical system, electronics and instrumentation, and software control.

1. Hydraulic System:
The hydraulic system features a main and duplicate circuit with separate hydraulic power packs to reduce noise and vibration. The system is equipped with quick disconnect couplings (QCDC), oil sampling ports, and filter banks. It also includes automatic pressure control valves and digital pressure transducers for precise fluid regulation. The hydraulic power pack is located separately to minimize disturbances.

2. Mechanical System:
The test bench is designed with robust loading springs that generate adjustable test loads according to requirements. Test components are mounted on the test table using mechanical fixtures. The system incorporates load cells and linear variable differential transformers (LVDT) to measure load and displacement accurately.

3. Electronics, Instrumentation & Control:
The instrumentation system automates the control and monitoring of critical parameters, including pressure, temperature, and leakage rates. It uses digital flow indicators, temperature sensors, and pressure transducers integrated with the data acquisition system (DAS) for real-time data logging and display.

4. Software and Automation:
The control software is developed on LabVIEW 8.1 and features a graphical interface for intuitive operation.
It supports connectivity with multiple hardware protocols such as GPIB, PXI, RS-232, and RS-485. Operators can execute tests through a 17-inch TFT touch-screen, which provides access to test parameters, test sequences, and result visualization. The software offers both manual and fully automatic modes, with extensive password protection for different levels of access.

Operational Modes
1. System Maintenance Mode:
In this mode, operators can perform sensor calibration, system diagnostics, and fault isolation. The system supports both automatic troubleshooting and manual diagnostics through dedicated software tools.

2. Test Part (UUT) Mode:
This is the primary testing mode, where dynamic testing of Units Under Test (UUT) takes place. The system runs pre-configured test sequences and provides real-time feedback on performance parameters. Operators can select and execute tests via the touch-screen interface, with results displayed on dual color monitors for easy reference.

Why Choose Our CCU Test Rig?
Our CCU Test Rig is built for organizations that demand precision, reliability, and automation in aerospace

Combined Control Unit (CCU) Test Rig for Aviation and Defense Applications component testing. Designed to handle high-pressure hydraulic systems, complex servo control testing, and dynamic performance simulations, it ensures that your components meet the highest standards of safety and functionality.

The system is ideal for companies involved in aviation manufacturing, military equipment testing, defense contractor support, and hydraulic system engineering. It offers unparalleled flexibility with both automated and manual test configurations, making it a versatile tool for various testing scenarios.