Details

Introduction
The General Purpose Pneumatic Test Rig is a high-performance, computer-controlled test system developed to conduct comprehensive performance evaluation, validation, and qualification of pneumatic systems and components. Designed for aerospace, defense, and high-reliability industrial applications, this rig provides engineers and technicians with the ability to precisely replicate operating conditions, measure critical performance parameters, and ensure compliance with international quality and safety standards.

Modern aircraft and defense platforms rely extensively on pneumatic systems for actuation, braking, pressurization, emergency systems, and auxiliary operations. Any malfunction in these systems can compromise mission safety. This rig is therefore engineered to perform end-to-end testing of valves, actuators, regulators, control units, manifolds, and complete pneumatic assemblies with a level of accuracy, repeatability, and reliability that exceeds manual inspection or basic bench setups.

System Overview
The rig integrates mechanical, pneumatic, electronic, and software subsystems into a robust and modular platform. Its dual pressure line configuration allows both high-pressure (up to 200 kgf/cm2) and low-pressure (up to 8 kgf/cm2) operations, enabling it to simulate a wide variety of operating conditions. The working fluid is ultra-clean, dry compressed air, conditioned with a dew point of -55°C and filtered to a particle purity better than 2 microns. This ensures the elimination of contaminants and moisture, protecting sensitive pneumatic components and yielding accurate, repeatable test results.

Key system highlights include:
• High-accuracy electronic flow meters for real-time flow measurement.
• Digital pressure transducers and sensors to capture minute pressure variations and leakages.
• Fully automated test sequencing software with programmable routines for different components.
• PC-based data acquisition and control system for real-time monitoring, test control, and archival of test data.
• Safety interlocks, overpressure protection, and emergency shut-off features to safeguard both the equipment and operator.

Functional Capabilities
The General Purpose Pneumatic Test Rig is capable of performing a broad spectrum of tests, such as:
1. Leakage (Air Tightness) Tests
   ▹ Detects micro-leakages in pneumatic circuits, valves, and actuators.
   ▹ Capable of performing both static leak tests (at fixed pressures) and dynamic leak tests (under flow).

2. Flow Measurement & Characterization
   ▹ Determines flow coefficients (Cv values) and verifies rated flow capacity.
   ▹ Characterizes pressure vs. flow behavior under varying load conditions.

3. Pressure & Overload Testing
   ▹ Simulates operational pressure cycles.
   ▹ Validates burst pressure and withstand pressure of components.

4. Functional Performance Testing
   ▹ Checks response times of valves, regulators, and actuators.
   ▹ Verifies operational efficiency and functional integrity.

5. Efficiency & Performance Benchmarking
   ▹ Compares actual vs. theoretical performance.
   ▹ Enables early detection of design or manufacturing defects.

Software & Automation
A critical feature of the rig is its customized software platform, designed for automation, repeatability, and advanced data analysis.
• Pre-programmed Test Routines: Standardized test procedures for common pneumatic components (valves, regulators, actuators) reduce operator input and error.
• Customizable Test Sequences: Engineers can create bespoke test programs for specialized components.
• Data Logging & Storage: Complete test data (flow, pressure, leakage, response time) is stored in a secure database.
• Data Visualization: Graphical user interface (GUI) allows real-time display of test curves, performance graphs, and live monitoring dashboards.
• Report Generation: Test results can be automatically compiled into PDF/Excel reports for traceability, customer handover, and audit compliance.
• Calibration & Diagnostics: Integrated self-check and calibration modules ensure long-term accuracy and compliance with standards.

Applications
The versatility of the General Purpose Pneumatic Test Rig makes it indispensable across multiple domains:

Aerospace & Defense
• Testing of aircraft pneumatic valves, pressure regulators, and actuators.
• Validation of emergency pneumatic circuits (landing gear, canopy release, oxygen supply).
• Inspection of flow and leakage parameters in weapon system pneumatic controls.

Manufacturing & Quality Assurance
• End-of-line functional testing of pneumatic components.
• Batch-level validation for OEMs supplying aerospace/defense components.

Maintenance, Repair & Overhaul (MRO)
• Verification of pneumatic system integrity during scheduled maintenance cycles.
• Troubleshooting defective units without the need for destructive testing.

Research & Development
• Characterization of new pneumatic designs.
• Academic and defense lab testing for prototype evaluation.

Industrial Pneumatics
• Performance verification of automation pneumatics in automotive, railways, and heavy engineering.

Advantages
• High-Precision Measurements: Superior accuracy with state-of-the-art sensors and flow meters.
• Wide Operating Range: Dual pressure system (8 kgf/cm2 low pressure & 200 kgf/cm2 high pressure).
• Automation & Repeatability: Pre-programmed software eliminates manual inconsistencies.
• International Standards Compliance: Designed to align with ISO 8573 (air quality), ISO 6358 (pneumatic flow measurement), and MIL-STD aerospace testing standards.
• Safety & Reliability: Fail-safe shutdown, overpressure protection, and operator safeguards.
• Data-Driven Testing: Full traceability and export-ready reports for audits and certifications.
• Scalability: Modular design allows additional test modules for future upgrades.

Technical Specifications

  

    
S. No.
    
Characteristic
    
Specification
  
  

    
1
    
Working Fluid
    
Clean dry air with dew point -55 °C
  
  

    
2
    
Purity of Working Fluid
    
Better than 2 microns
  
  

    
3
    
Pressure Range (High Line)
    
Up to 200 kgf/cm²
  
  

    
4
    
Pressure Range (Low Line)
    
Up to 8 kgf/cm²
  
  

    
5
    
Flow Measurement
    
High-accuracy electronic flow meters (±0.5% FS)
  
  

    
6
    
Pressure Measurement
    
Digital pressure sensors, range up to 250 kgf/cm²
  
  

    
7
    
Data Acquisition
    
Computer-based with automated test sequencing
  
  

    
8
    
Software Interface
    
GUI-based, customizable test programs, data storage
  
  

    
9
    
Report Output
    
Automated report generation (Excel/PDF)
  
  

    
10
    
Safety Features
    
Overpressure protection, emergency shut-off, redundant sensors
  
  

    
11
    
Power Supply
    
Standard 230V AC / 50 Hz (customizable)
  
  

    
12
    
Compliance
    
ISO 8573, ISO 6358, MIL-STD aerospace requirements
  


Conclusion
The General Purpose Pneumatic Test Rig is more than just a testing machine — it is a mission-critical quality assurance platform that ensures the reliability, safety, and performance of pneumatic systems. By combining cutting-edge instrumentation, automated data handling, and compliance with aerospace standards, it provides organizations with a powerful tool to validate designs, optimize manufacturing, and support MRO activities.

Its versatility, accuracy, and automation make it ideal for aerospace OEMs, defense contractors, research laboratories, and industrial users who demand uncompromising quality and traceability.