Details

The BMP Pump Test Rig with Jib Crane is a highly specialized, precision-engineered testing system designed for comprehensive performance evaluation of gear pumps and other hydraulic components. This advanced test rig is developed by Neometrix Group, a leading provider of aerospace, defence, and industrial test equipment.

Designed to meet the stringent requirements of industrial and military applications, this state-of-the-art hydraulic pump testing system integrates high-performance motors, hydraulic control systems, automated PLC-based monitoring, and real-time data acquisition capabilities. The inclusion of a jib crane facilitates easy loading, positioning, and unloading of heavy pump components, thereby enhancing operational efficiency and workplace safety.

The BMP Pump Test Rig is built for precision testing, performance validation, endurance evaluation, and quality assurance of various hydraulic pumps used in defence vehicles, aerospace applications, railway systems, and heavy machinery.

2. Key Features & Components
The BMP Pump Test Rig with Jib Crane integrates multiple hydraulic, mechanical, electrical, and electronic subsystems, making it a versatile and advanced test setup.
2.1 Hydraulic System
  • High-Capacity Hydraulic Oil Reservoirs:
   - Main reservoir (150 liters) for hydraulic oil storage.
   - Collection tank (50 liters) to manage and analyze tested oil.
   - Level Gauge for real-time oil level monitoring.

  • Pump and Motor Configuration:
   - Primary Testing Pump: Driven by a high-power 5.5 kW motor (M1), capable of high-pressure pump testing.
   - Charging Pump: Operated by a 3.7 kW motor (M2), responsible for pressurizing the hydraulic circuit.
   - Vane Pump: Designed with a displacement of 22 cm3/rev and a maximum operating pressure of 17.5 kg/cm2.

  • Filtration & Contaminant Control:
   - Advanced 10-micron filtration system ensures clean fluid circulation.
   - Filter clogging indicator switch provides real-time contamination alerts.
   - Manually operated precision ball valves for fluid flow regulation.

  • Temperature & Heat Control Mechanisms:
   - High-efficiency oil heater (4.0) to maintain optimum fluid temperature.
   - RTD Temperature Sensors (3.1) for precise oil temperature monitoring.
   - Industrial-grade heat exchanger & 12 TR capacity chiller to regulate hydraulic fluid temperature and prevent overheating.

  • Pressure Regulation & Monitoring:
   - High-accuracy pressure transmitters (11.1, 11.2) provide real-time pressure readings.
   - Adjustable relief valve (10.0) prevents system overpressure and ensures safe operation.
   - Precision pressure gauges (PG-1, PG-2) for direct manual pressure monitoring.

  • Flow Rate Measurement & Analysis:
   - High-precision flow meter at the pump outlet to accurately measure fluid displacement and flow rate under test conditions.

2.2 Mechanical System
  • Heavy-Duty Belt Power Transmission System:
   - Ensures efficient power transfer from motor to pump.
   - Minimizes energy losses and ensures high mechanical reliability.

  • Rugged Testing Pump Fixture (17.0):
   - Engineered for high durability and quick, secure mounting of test pumps.
   - Allows repeatable testing without alignment errors.

  • Integrated Jib Crane:
   - Facilitates easy handling, positioning, and installation of heavy pumps.
   - Reduces manual handling risks, enhancing workplace safety and operational efficiency.

2.3 Advanced Electrical & Control System
  • HMI-Based Digital Control Panel:
   - User-friendly touch screen interface for complete system control.
   - Provides real-time monitoring of pressure, temperature, flow rates, and motor performance.
   - Allows test parameter configuration and result visualization.

  • Fully Automated PLC-Based Operation:
   - Eliminates human error by automating test sequences and safety interlocks.
   - Real-time data acquisition, storage, and logging for post-test analysis.
   - Integrates with SCADA systems for remote monitoring and reporting.

  • Advanced Safety Interlocks & System Protection:
   - Automated shutdown system for overpressure, overheating, or abnormal conditions.
   - Hooter & tower light alarms for immediate operator alerts.
   - Emergency stop buttons for instant system shutdown.
   - Fail-safe valve and power cut-off interlocks for enhanced safety.

  • Dual Operating Modes – Local & Remote Control:
   - Local Mode: On-site operation using the HMI panel.
   - Remote Mode: Allows integration with industrial control networks for remote operation and automated test execution.

3. Operating Procedure
The BMP Pump Test Rig follows a systematic and controlled operating process, ensuring reliable and repeatable pump testing.
Step 1: System Pre-Check & Setup
   - Inspect and verify all hydraulic, mechanical, and electrical connections.
   - Ensure manual ball valve (6.0) is open for proper hydraulic flow.
   - Check and confirm pre-configured test parameters on the HMI.

Step 2: System Startup
   - Press the Start Button on the HMI control panel.
   - The electrically actuated valve opens, initializing the filling operation.
   - The PLC system checks for clogged filters and alerts if necessary.

Step 3: Pump Testing Procedure
   - Select between Local or Remote Operation.
   - Set up desired test parameters for pressure, temperature, and flow rate.
   - Start the pump motor to simulate real-world operating conditions.

Step 4: Automated Performance Monitoring
   - Pressure and temperature sensors continuously track system behavior.
   - The flow meter records fluid displacement and test results.
   - Live data is displayed on the HMI, and test reports are generated.

Step 5: Controlled System Shutdown
   - The PLC controller stops the system once test conditions are met.
   - All test data logs are securely stored for post-test analysis.

4. Safety Features
  • Automated Pressure & Temperature Regulation:
   - High-precision relief valves ensure safe pressure levels.
   - Automated thermal cutoff prevents overheating.

  • Electrically Insulated Wiring & Components:
   - All electrical panels and motors are fully insulated and grounded.
   - Certified industrial-grade safety compliance.

  • Redundant Fail-Safe Mechanisms:
   - Secondary containment system prevents hydraulic fluid leaks.
   - Backup power interlocks prevent damage during sudden power loss.

  • Real-Time Alarms & Warnings:
   - Tower light & audible alarm system for instant fault detection.
   - Live error messages displayed on the HMI panel.

5. Applications
The BMP Pump Test Rig with Jib Crane is an indispensable tool for industries requiring high-precision hydraulic pump validation, including:
1. Aerospace & Defense:
   - Testing hydraulic pumps for military aircraft, helicopters, and ground vehicles.
   - Validation of fluid power systems in defense applications.

2. Automotive & Heavy Machinery:
   - Performance testing of hydraulic pumps in railways, construction, and industrial equipment.
   - Endurance testing for automotive power steering and hydraulic braking systems.

3. Manufacturing & Industrial R&D:
   - Prototype testing of new pump designs.
   - Quality control for mass-produced hydraulic pumps.

4. Oil & Gas Sector:
   - Testing high-pressure hydraulic pumps used in oil refineries and drilling platforms.
   - Ensuring compliance with international safety and performance standards.

6. Conclusion
The BMP Pump Test Rig with Jib Crane is a cutting-edge, fully automated hydraulic testing system designed for high-precision pump evaluation. Its PLC-based control, real-time monitoring, and integrated safety interlocks make it an essential solution for aerospace, defense, automotive, and industrial sectors.

With its robust construction, advanced automation, and precision engineering, this test rig provides unparalleled accuracy, reliability, and safety in hydraulic pump testing.