Hydraulic Loading System

Hydraulic Loading System and Pump Test Rig – Advanced Performance and Qualification The Hydraulic Loading System and Pump Test Rig are precision platforms designed for high-pressure hydraulic pump testing, performance validation, and endurance qualification across aerospace, defense, and industrial applications. Engineered for accuracy and reliability, these systems support comprehensive hydraulic pump testing under controlled conditions. Core features include high-pressure test benches, flow control orifices, skid-mounted test stands, and endurance cycling capabilities, enabling thorough evaluation of pump efficiency, pressure response, and fatigue life. PLC-controlled hydraulic rigs and modular test systems allow automated testing sequences, precise monitoring, and scalable setups. Additional functionalities include oil temperature control, accumulator damping, and energy recovery systems for optimized operation. Designed for specialized applications, the rig supports aerospace pump qualification, defense hydraulic testing, and industrial pump bench evaluation. Advanced safety and convenience features include automated safety interlocks, quick-swap orifices, remote diagnostics, and calibration routines. Compact, noise-reduced enclosures enhance usability in laboratory and field environments, while compatibility with MIL-H-5606 ensures adherence to industry standards. Trending solutions also highlight fatigue testing machines, modular hydraulic systems, and high-precision performance validation rigs, offering reliable, repeatable, and safe testing for pumps in demanding operational scenarios.

About

The Hydraulic Loading System (HLS) from Neometrix Defence Limited is a fully modular, skid-mounted test rig designed to replicate the demanding operating conditions of engine-driven hydraulic pumps across aerospace, defense, industrial, marine and energy applications. Comprising eight plug-and-play modules—including oil reservoir and conditioning, air regulation, inlet/outlet flow control, loading valve cycling, heat exchange, and portable filling assemblies—the HLS delivers precisely controlled back-pressures up to 295 bar and flow rates from 20–210 LPM while maintaining oil temperatures within tight tolerances. Its high-accuracy instrumentation (±0.5% pressure, ±1% flow), programmable PLC/HMI control, automated safety interlocks and integrated energy-recovery, calibration and noise-reduction features ensure repeatable, data-driven performance validation and endurance cycling. Built from corrosion-resistant steels, aerospace-grade seals, and vacuum-insulated piping, the HLS offers turnkey pump qualification, fatigue testing, quality assurance and training capabilities with remote diagnostics and a compact footprint for rapid deployment in even space-constrained facilities.

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Technical Details

Specifications

▹ Maximum Design Pressure: 340 kg/cm2 (≈4,834 psi)
▹ Working Pressure Range: 270–295 kg/cm2 (≈3,837–4,195 psi)
▹ Flow Capacity: 20–210 LPM (≈5.3–55 gpm)
▹ Hydraulic Fluid: MIL-H-5606/FH-51 (Density 0.8735 kg/L @ 15.6 °C)
▹ Kinematic Viscosity: 15 cSt @ 40 °C
▹ Reservoir Volume: 175 L; pressurization up to 10 kg/cm2
▹ Temperature Limits: Inlet ≤ 80 °C; Outlet ≤ 100 °C
▹ Air Supply: 6–10 kg/cm2 (≈85–142 psi)
▹ Power Requirements: 3-phase 415 VAC, 50 Hz, 10 kW
▹ Control Interface: 7′′ HMI, PLC with Ethernet, USB export

Applications

▹ Aerospace Pump Qualification: Meets FAR/JAR environmental and endurance testing standards for aircraft hydraulic systems.
▹ Defense Vehicle Systems: Validates performance of armored-vehicle hydraulic drives under varying loads.
▹ Industrial Machinery R&D: Benchmarks pump efficiency, cavitation margins, and transient response for equipment manufacturers.
▹ Maintenance & Overhaul Shops: Rapid acceptance tests on rebuilt pumps to ensure return-to-service reliability.
▹ Marine & Offshore Systems: Simulates salt-water and high-pressure conditions to qualify pumps used in ships, rigs, and subsea applications.
▹ OEM Production Quality Assurance: Integrates into assembly lines for end-of-line functional testing of newly manufactured hydraulic pumps.
▹ Mobile Hydraulic Equipment Validation: Tests pumps for excavators, cranes, and agricultural machinery under real-world duty cycles.
▹ Educational & Training Facilities: Serves as a hands-on training rig for vocational institutes and OEM service centers to teach hydraulic system diagnostics.
▹ Energy Sector Applications: Validates pump performance for hydroelectric, solar-tracking, and wind-pitch control systems under cyclical loads.

FAQ

Details

Introduction
The Hydraulic Loading System (HLS) by Neometrix Defence Limited is a purpose-built test rig engineered to replicate the demanding operating conditions of engine-driven hydraulic pumps. It delivers a controlled, variable back-pressure to the pump outlet, allowing precise simulation of real-world loading profiles encountered in aerospace, defense, and industrial applications. By integrating high-accuracy sensors and instrumentation, the HLS enables comprehensive performance validation, endurance cycling, and fault-finding under repeatable, traceable conditions—key steps in qualifying pumps for flight, marine, or heavy-equipment service.

System Composition
The HLS is organized into eight skid-mounted, plug-and-play modules, each fulfilling a critical subsystem role:
1. Oil Tank Module: 175 L reservoir with level transmitter and over-temperature switch; in-line 5 μm filters.
2. Air Regulation Module: Delivers up to 10 kg/cm2 for accumulator charging and pneumatic controls.
3. Inlet Module: Monitors suction pressure (< 10 bar) and optionally pre-heats oil for viscosity stability.
4. Outlet Module: Variable orifice bank and fine flow control valve for precise back-pressure adjustment.
5. Drain Module: Handles return flow up to 30 bar, venting back to the reservoir.
6. Loading Valve Module: Pneumatically actuated manifold with nitrogen accumulator for rapid pressure cycling.
7. Heat Exchanger Module: PID-controlled shell-and-tube exchanger maintaining outlet ≤ 100 °C and inlet ≤ 80 °C.
8. Portable Oil Filling Module: 50 L trolley-mounted tank with pump and metering system for quick top-ups.

Working Principle
1. Fluid Supply & Conditioning: Oil conforming to MIL-H-5606/FH-51 is filtered (5 μm) and temperature-controlled.
2. Suction Control: Inlet pressure transmitter prevents cavitation by ensuring suction stays < 10 bar.
3. Load Imposition: Selectable orifices and a high-resolution globe valve create back-pressure between 270–295 bar.
4. Temperature Management: PID-regulated coolant flow in heat exchanger stabilizes oil temperature within ± 2 °C.
5. Data Acquisition & Control: PLC/HMI logs pressure, temperature, and flow; executes custom test scripts and alarms.

Technical Specifications
▹ Maximum Design Pressure: 340 kg/cm2 (≈4,834 psi)
▹ Working Pressure Range: 270–295 kg/cm2 (≈3,837–4,195 psi)
▹ Flow Capacity: 20–210 LPM (≈5.3–55 gpm)
▹ Hydraulic Fluid: MIL-H-5606/FH-51 (Density 0.8735 kg/L @ 15.6 °C)
▹ Kinematic Viscosity: 15 cSt @ 40 °C
▹ Reservoir Volume: 175 L; pressurization up to 10 kg/cm2
▹ Temperature Limits: Inlet ≤ 80 °C; Outlet ≤ 100 °C
▹ Air Supply: 6–10 kg/cm2 (≈85–142 psi)
▹ Power Requirements: 3-phase 415 VAC, 50 Hz, 10 kW
▹ Control Interface: 7′′ HMI, PLC with Ethernet, USB export

Key Features
▹ Modular Skid Design for rapid relocation and reconfiguration.
▹ High-Accuracy Instrumentation with ± 0.5% pressure and ± 1% flow accuracy.
▹ Customizable Test Profiles (static, ramp, step, sine waveforms).
▹ Automated Safety Interlocks on over-pressure, over-temperature, low-oil-level.
▹ Quick-Swap Orifice Sets minimizing downtime.
▹ Remote Monitoring & Diagnostics via Modbus/ProfiNet for IIoT integration.

Applications
▹ Aerospace Pump Qualification: Meets FAR/JAR environmental and endurance testing standards for aircraft hydraulic systems.
▹ Defense Vehicle Systems: Validates performance of armored-vehicle hydraulic drives under varying loads.
▹ Industrial Machinery R&D: Benchmarks pump efficiency, cavitation margins, and transient response for equipment manufacturers.
▹ Maintenance & Overhaul Shops: Rapid acceptance tests on rebuilt pumps to ensure return-to-service reliability.
▹ Marine & Offshore Systems: Simulates salt-water and high-pressure conditions to qualify pumps used in ships, rigs, and subsea applications.
▹ OEM Production Quality Assurance: Integrates into assembly lines for end-of-line functional testing of newly manufactured hydraulic pumps.
▹ Mobile Hydraulic Equipment Validation: Tests pumps for excavators, cranes, and agricultural machinery under real-world duty cycles.
▹ Educational & Training Facilities: Serves as a hands-on training rig for vocational institutes and OEM service centers to teach hydraulic system diagnostics.
▹ Energy Sector Applications: Validates pump performance for hydroelectric, solar-tracking, and wind-pitch control systems under cyclical loads.

Construction & Materials
Frame & Skid: Carbon-steel with epoxy powder-coat finish.
Pressure Piping: Stainless-steel 316L tubing and fittings rated to 400 bar.
Valve Manifolds: Austenitic stainless-steel blocks with precision ports.
Heat Exchanger: Copper-nickel tubes in stainless-steel shell.
Seals & Hoses: PTFE seals and reinforced hoses rated to 350 bar.

Conclusion
Neometrix’s Hydraulic Loading System sets the benchmark for hydraulic pump testing by combining modular flexibility, precise control, and comprehensive safety features. It delivers repeatable, data-driven insights critical for reliability and performance in aerospace, defense, and industrial applications.