Details

1. Introduction & Purpose
The Inertial Loading Test Facility is a fully integrated system designed to subject hydraulic actuators, manifolds, and power packs to precisely controlled inertial loads that emulate real-world dynamic conditions. Rather than relying solely on static pressures, this facility uses interchangeable mass blocks and high-response hydraulic control to reproduce acceleration, velocity, and force profiles representative of actual service environments. This capability ensures that your components are validated not just for pressure endurance but for fatigue life and control fidelity under true dynamic loading.

2. Applications
This versatile test rig serves a broad array of industries:
• Aerospace & Defense: Qualify flight-control actuators through repeated cyclic loading that replicates maneuvers, ensuring reliability in extreme conditions.
• Heavy Machinery: Validate hydraulic cylinders and rotary actuators used in cranes, excavators, and presses for long-term durability under changing inertial forces.
• Automotive: Test braking and steering hydraulic assemblies under rapid acceleration/deceleration cycles to verify response time and structural integrity.
• Energy & Power Generation: Fatigue-test hydraulic power units in turbines and offshore platforms, simulating load reversals common in start-stop and load-shedding scenarios.

3. Core Components & Features
3.1 Reaction Brackets
The heart of the structure comprises dual reaction brackets—one horizontal, one vertical—fabricated from IS-2062 mild steel and bolted to your facility’s strong floor and shear wall. Each bracket is reinforced with closely spaced ribs to withstand dynamic loads of ±160 kN at the actuator’s center line, minimizing frame deflection and eliminating spurious resonances during high-speed testing .

3.2 Antifriction Guide & Modular Mass Blocks
A precision antifriction guide allows the mass carriage to travel ±150 mm horizontally and ±100 mm vertically. Hardened guide rails and recirculating bearings ensure positional accuracy down to 2 μm over every 1 000 mm of travel, even at accelerations up to 2 g and velocities approaching 2 m/s. The inertial load is applied via modular mass blocks in 500 kg increments, up to a total of 2 000 kg, with the center-of-gravity maintained precisely on the actuator axis for repeatable, balanced loading .

3.3 Hydraulic Actuation System
Two three-stage servo valves, each capable of 60 L/min at 210 bar, work in concert with four strain-gauge pressure transmitters (ranges 0–400 bar and 0–700 bar, ±0.1 % full-scale accuracy) to create a closed-loop control environment. All hydraulic piping is butt-welded and radiographed in accordance with ASME Section IX, and hoses meet SAE 100R11 and 100R8 standards. This robust hydraulic interface delivers rapid, precise control of position, velocity, and acceleration, even under full inertial load .

3.4 Control & Data Acquisition
An industrial-grade PLC runs at a 1 kHz control loop frequency over EtherCAT, ensuring millisecond-level response. A 12′′ capacitive touchscreen HMI provides intuitive test setup, live trend graphs, and alarm handling. Data acquisition is handled by a 16-channel, 24-bit DAQ system sampling up to 5 kS/s per channel, capturing encoder position (1 μm resolution), pressure signals (4–20 mA or ±10 V), and optional accelerometer inputs for advanced analysis.

4. Technical Specifications

  

    
Parameter
    
Specification
  
  

    
Reaction Force Capacity
    
±160 kN dynamic in horizontal & vertical axes
  
  

    
Structural Natural Frequency
    
≥ 100 Hz
  
  

    
Inertial Mass Blocks
    
500 kg increments up to 2,000 kg; CG on actuator axis
  
  

    
Travel Stroke
    
Horizontal ±150 mm; Vertical ±100 mm
  
  

    
Guide Performance
    
≤ 2 g acceleration; ≤ 2 m/s speed; 2 µm/1,000 mm accuracy; –20 °C to +80 °C; 80 kN dynamic rating
  
  

    
Hydraulic Supply
    
0–350 bar; up to 200 L/min flow
  
  

    
Actuator Ports & Hoses
    
SAE 100R11 (1¼″ horizontal, 1″ vertical); SAE 100R8 (⅜″ pilot/drain)
  
  

    
Servo Valves
    
2 × three-stage flow control; 60 L/min @ 210 bar
  
  

    
Pressure Transmitters
    
4 × ranges (0–400 bar, 0–700 bar); ±0.1% FS
  
  

    
Control & DAQ
    
PLC 1 kHz loop; EtherCAT; 12″ HMI; 16-ch, 24-bit DAQ @ 5 kS/s
  
  

    
Material & Weld Standards
    
IS-2062 mild steel; ASME Sec IX radiographed welds
  
  

    
Power & Utilities
    
400 VAC ±10%, 50 Hz, 3-phase + N + PE, 10 kVA; 6 bar dry air
  
  

    
Footprint & Weight
    
4 m × 2 m × 2.5 m; approx. 3,500 kg
  
  

    
Environment
    
–20 °C to +60 °C operating; 5%–95% RH non-condensing
  


5. Scope of Supply & Work
Our turnkey delivery encompasses end-to-end services. We begin with detailed 3D and fabrication drawings, complete with QA/QC procedures and inspection schedules for your approval. Upon drawing sign-off, we procure all raw materials, servo valves, transducers and specialty components, followed by precision CNC machining and radiographic weld inspection. Assembly and factory acceptance testing (FAT) include structural natural-frequency checks, deflection under dynamic loads, and full inertial-mass performance tests.

Finally, our field team handles on-site installation—bolting reaction brackets, connecting hydraulic and electrical interfaces, flushing the system, and conducting site acceptance tests (SAT) with prototype actuators and manifolds.

6. Testing & Performance Evaluation
Performance evaluation goes beyond static measurements. We execute closed-loop position, velocity, and acceleration tracking tests, ensuring deviations remain within 5 % of commanded profiles under full inertial mass. A sine-sweep test from 0.1 Hz to 50 Hz at 0.2 mm amplitude verifies –3 dB bandwidth compliance. End-of-stroke cushioning and lateral-load tests confirm pressure rises and side forces remain within design limits. Hydrostatic bearing leakage and high-pressure reciprocation tests validate long-term sealing and guide performance.

7. Deliverables & Warranty
Upon completion, you receive the fully assembled Inertial Loading Test Facility, a comprehensive spare-parts kit (filters, seals, connectors), as-built drawings, calibration certificates, FAT/SAT reports, and detailed operating and maintenance manuals. We back our workmanship and all bought-out items with a 12-month warranty from dispatch, including on-site support and remote diagnostics.

8. Benefits & Differentiators
• True Dynamic Validation: Simultaneously tests pressure control and inertial loading to reveal fatigue and control issues early.
• Modular & Adaptable: Quickly reconfigure inertial mass, stroke, and test profiles for different actuator sizes and use cases.
• High Precision: Sub-micron accuracy and a stiff frame (≥ 100 Hz natural frequency) eliminate testing artifacts.
• Seamless Integration: Pre-wired control cabinet tested software packages, and fieldbus communications for rapid commissioning.
• Global Compliance: Engineered and tested to ASME, ISO, CE, and ANSI standards with certified components.