Details

Overview
The Integration Simulator is a fully engineered, high-fidelity test and training environment designed for the integration, evaluation, and verification of complex defence and aerospace systems. Developed to meet stringent military and R&D requirements, it provides a controlled space for mechanical, electrical, and software systems to be tested together under realistic yet safe conditions.

With a robust modular architecture, precise mechanical assemblies, and advanced control and data-logging capabilities, this simulator enables mission rehearsal, operator training, and performance validation across a wide range of applications.

Applications
• Systems integration testing for defence and aerospace hardware
• Verification of release and deployment mechanisms
• Operator and crew training under realistic simulated conditions
• Data logging, telemetry validation, and post-mission analysis
• Controlled environmental testing of mechanical assemblies and actuators

Key Features
Customised Structural Design
• Built from high-strength aerospace alloys and high-grade structural steel for durability and load-bearing performance.
• CNC-machined components with corrosion-resistant surface treatments for long-term service.
• Modular frame and panel construction allowing reconfiguration and upgrades.
• Fire-rated access doors and marine-grade flooring for safety and durability.
• Thermal- and sound-insulated wall and ceiling panels for controlled conditions.

Dedicated Functional Areas
• Simulation Area – Houses the primary mechanical assemblies, actuators, suspension points, and interfacing fixtures. 
• Control Console Area – Equipped with industrial-grade stainless steel enclosures, operator-friendly desks, and high-resolution displays for real-time control and monitoring.
• Data Recording & Monitoring Area – Workstations with high-performance processors, large storage capacity, and multi-screen setups for detailed analysis.
• Storage & Utilities – Shelving, secure storage, and maintenance toolkits for operational readiness.

Environmental Control
• High-capacity HVAC system with precise temperature and humidity control for optimal equipment performance.
• HEPA-filtered air purification for dust and particulate removal.
• Oscillating wall-mounted fans and an air curtain at the entry to maintain air quality and minimise contamination.
• Noise-controlled, insulated structure for comfortable and safe operation.

Electrical & Networking Infrastructure
• Regulated DC power rails (5V, 12V, 24V, 28V) supported by industrial SMPS units for different subsystem requirements.
• Modular, labelled power outlets and ISI-certified switchgear for safety and ease of use.
• High-speed network cabling infrastructure for secure data transfer between subsystems and control stations.
• Integrated lighting plan for uniform, shadow-free illumination across all working zones.

Control & Data Systems
• Operator Consoles with ergonomic design, anti-glare HD displays, and industrial computing hardware for real-time simulation management.
• Data Recording Systems with solid-state primary storage and large-capacity HDD backup for long-term test data retention.
• Large-Format Review Displays for group analysis, training, and after-action review.
• Fully integrated CCTV surveillance with HD, IR-enabled cameras and long-term video storage capability.

Mechanical Assemblies & Test Fixtures
• Precision-engineered door and latch mechanisms, clamps, mounting brackets, and suspension assemblies to replicate actual deployment hardware.
• Load-bearing brackets, bulkheads, and structural frames designed to handle operational forces safely.
• Electromechanical actuators with sensor feedback for accurate motion control.
• Modular mechanical sub-assemblies to support a variety of test articles and scenarios.

Safety Systems
• Fire detection and suppression equipment, including multiple classes of fire extinguishers.
• Controlled-access entry systems with biometric authentication.
• Fail-safe design for critical load-bearing and release mechanisms.
• Insulated marine-grade flooring for electrical and operational safety.

Technical Highlights

  

    

      
Category
      
Specification
    
  
  

    

      
Overall Height
      
~2.9 m
    
    

      
Panel Construction
      
Insulated sandwich panels with coated steel skins
    
    

      
Frame Materials
      
High-strength alloy steel, aerospace-grade aluminium, titanium components
    
    

      
Zones
      
Simulation, Control, Data Recording, Storage
    
    

      
HVAC
      
Precision cooling & dehumidification with HEPA filtration
    
    

      
Power Rails
      
5V, 12V, 24V, 28V DC regulated outputs
    
    

      
Networking
      
High-speed structured cabling with RJ45 connectivity
    
    

      
Surveillance
      
Multi-camera HD CCTV with long-term DVR storage
    
    

      
Lighting
      
LED luminaires for uniform zone illumination
    
    

      
Safety
      
Fire-rated doors, extinguishers, biometric access
    
    

      
Control Consoles
      
Stainless steel enclosures, Xeon-class processors, HD displays
    
  


Advantages
• High-Fidelity Simulation – Accurately replicates operational dynamics of real-world defence systems.
• Operator-Centric Design – Ergonomics, environmental control, and safety built in.
• Data-Driven Testing – Comprehensive capture and replay of operational data.
• Scalable & Upgradeable – Modular architecture supports evolving mission requirements.
• Robust & Reliable – Built with military-grade materials and manufacturing standards.