Dual Power Hydraulic Test Rig, failover-rated to 350 bar / 80 LPM.

Introduction

The Neometrix Dual Power Hydraulic Test Rig is purpose-built to serve as the definitive verification platform for hydraulic Line-Replaceable Units (LRUs) deployed in the most demanding aerospace and defense environments. In plain terms, it is a highly sophisticated stress-test bench that applies controlled bursts of hydraulic fluid — even beyond normal operating limits — so that engineers can identify leaks, mechanical weaknesses, or performance drifts before components ever leave the factory. By reproducing exact field conditions in the laboratory, this rig guarantees that critical systems such as landing-gear jacks, flight-control actuators and brake assemblies will operate reliably under all circumstances.

System overview

The Dual Power Hydraulic Test Rig integrates two fully independent hydraulic power systems, a large-volume fluid reservoir, comprehensive thermal conditioning and advanced digital controls into a single, turnkey solution. This architecture enables continuous operation — without interruption — for long-duration proof, burst, impulse and endurance sequences. All major components are mounted on a reinforced steel skid with integrated leveling feet and forklift channels, ensuring straightforward installation and mobility within any industrial test-cell environment.

Power units

1. Main power pack

• Pump type: Parker PV Plus axial-piston, 63 cc/rev, renowned for high volumetric efficiency and low noise levels.
• Electric drive: 60 HP (45 kW) TEFC motor, 4-pole design, delivering 1470 RPM at 415 VAC, 50 Hz.
• Performance envelope: continuous duty up to 350 bar at 80 LPM; certified safe-operating-limit up to 450 bar.
• Cooling: IP55 motor housing with external fan ensures thermal stability under continuous operation.

2. Standby power pack

• Pump type: high-pressure gear pump producing up to 80 LPM.
• Motor: secondary 15 kW TEFC motor; engages automatically upon detection of main-pump fault or scheduled maintenance.
• Pressure regulation: panel-mounted pilot relief valve adjustable from 10 to 200 bar, providing immediate load relief and maintaining test continuity.
• Fail-safe switching: pressure sensors and PLC logic manage seamless switchover with less than 2 seconds of downtime.

Hydraulic reservoir & thermal conditioning

• Reservoir construction: 400 L capacity fabricated from SS-304 stainless steel with anti-cavitation baffle and internal deflector plates to minimize aeration.
• Fluid monitoring: integrated level switch, manual sight glass and temperature probe provide real-time status.
• Chiller: air-cooled, 30,000 kcal/h unit maintains oil temperature between 10°C and 48°C to replicate arctic-to-desert climates.
• Heater: 4 kW immersion heater controlled via PID loop for ±0.1°C stability.
• Accumulator/dampener: 1 L piston-type unit smooths pulsations, ensuring steadier pressure delivery and more accurate test data.

Filtration & fluid quality

Maintaining hydraulic-fluid cleanliness is vital for repeatable, long-term testing. This rig employs six sequential filters:

Instrumentation & control

• Pressure sensing: dual-channel WIKA digital transducers (0–413 bar, ±0.25%) alongside analog Bourdon-tube gauges (0–600 bar, ±0.25%).
• Flow measurement: high-precision turbine meters in two ranges (3.6–36 LPM and 13.3–133 LPM, ±1% full-scale) mounted at both inlet and return circuits.
• Digital controller: Omron PLC with touchscreen HMI for setting pressure ramp rates, hold times and cycle counts; built-in sequence editor supports nested test loops and conditional branching (e.g., abort on leak detection); data logging via USB or Ethernet for full traceability and integration with MES/SCADA systems.
• Auxiliary power supply: APLAB DC source (0–35 V, 0–10 A) with digital readouts, ideal for testing electro-hydraulic actuators and solenoid valves.

Safety & compliance

• Relief & dump valves: pilot-operated relief valves set to 300 bar (main) and 200 bar (standby) automatically vent excess pressure; manual and solenoid-operated dump valves enable rapid depressurization.
• Emergency stop: four-zone E-Stop circuit with lockable pushbuttons strategically located around the skid.
• Electrical protection: main circuit breaker with ground-fault interrupter and motor-protection relays.
• Standards met: designed and manufactured under an ISO 9001 quality system; fully compliant with MIL-STD-810G environmental requirements and relevant aerospace-industry safety codes.

Test modes & functional capabilities

• 1. Proof & burst testing: ramp-to-pressure and hold sequences to verify vessel integrity.
• 2. Static & dynamic leakage: quantitative measurement of leakage flows under steady-state and pulsating conditions.
• 3. Pressure/flow characterization: automated sweeps of command-signal vs. output parameters for proportional valves, generating full flow–pressure curves.
• 4. Impulse & endurance cycling: configurable cycles (up to 10,000+ cycles) with dwell, rise/fall and dwell profiling.
• 5. Mechanical & electrical verification: micro-switch actuation tests, lever-force measurement, insulation-resistance checks and ground-bond integrity.

Installation & site requirements

• Footprint: 4.5 m (L) × 2.5 m (W) × 2.0 m (H).
• Electrical supply: 415 VAC, 3-phase, 50 Hz with neutral; recommended 80 kVA service capacity.
• Cooling water: clean water supply at 1 L/min, 20–30°C for chiller heat rejection (optional external radiator).
• Foundation: level concrete pad or vibration-isolated grating floor recommended.

Documentation & after-sales support

• Documentation package: comprehensive design-approval package, GA drawings, hydraulic schematics, electrical wiring diagrams, full bill of materials and calibration certificates.
• User manuals: step-by-step operation, maintenance procedures, troubleshooting guides and safety protocols.
• Calibration & service: pre-delivery factory acceptance test (FAT) and optional site acceptance test (SAT); annual calibration and service contracts available.
• Spare parts: standard and fast-turnaround kits; custom spares tailored to customer-specific configurations.

Conclusion

The Neometrix Dual Power Hydraulic Test Rig offers an uncompromising balance of redundancy, precision and operational safety, making it ideal for aerospace and defense organizations that need a dependable electric and diesel-class dual-drive hydraulic tester for production, MRO and R&D programmes. Two pumps. One skid. Zero downtime on failure.