Main Rotor Actuator Test Rig, built for 0-3000 psi proof pressure.

1. Introduction

The Main Rotor Actuator (MRA) Test Rig by Neometrix Group is an advanced hydraulic and electromechanical testing system designed for evaluating, calibrating, and validating the performance of Main Rotor Actuators (MRA) and Tail Rotor Actuators (TRA) used in Light Combat Helicopters (LCH) and other rotorcraft systems. It conducts proof pressure tests, leakage tests, load-speed assessments, drift speed analysis, and frequency response evaluations to ensure precise actuator functionality. Equipped with real-time data acquisition, PC-based control, and aviation-grade instrumentation, the rig meets military and aerospace standards for safety, reliability, and performance compliance.

Actuators play a critical role in controlling aircraft stability and maneuverability, making precise testing essential for flight safety, reliability, and regulatory compliance. This test rig provides real-time analysis of the actuators under various load, speed, and pressure conditions, ensuring they meet stringent operational standards.

2. Functions & capabilities

The MRA Test Rig performs comprehensive hydraulic, mechanical, and electrical testing, including:

A. Hydraulic Performance Tests

• Proof Pressure Test: ensures actuators can withstand operational pressure without failure.
• External & Internal Leakage Tests: identifies fluid leaks that may affect performance and safety.
• Load vs. Speed Characteristics Test (Loop Gain): measures actuator speed variation under different loads and computes feedback loop performance.
• No-Load Speed Test: evaluates actuator response and speed under zero-load conditions.
• Stall Load & Synchronization Test: ensures actuators maintain synchronization under high loads and stall conditions.
• Drift Speed Test: measures any unintended movement due to internal hydraulic inefficiencies.

B. Electrical & Control Performance Tests

• Pilot Input Load Measurement: determines force required to activate the actuator, simulating real pilot control inputs.
• By-Pass Anti-Jamming Test: checks resilience against potential mechanical jamming or obstruction.
• Auto Stabilizer Operation Test: verifies the performance of the stabilization system under real-time conditions.
• Frequency Response Test: analyzes the actuator’s dynamic response to different input signals to ensure proper control system tuning.

3. Key features & advantages

A. High-Precision Testing & Calibration

• Real-time performance monitoring for pitch, roll, and collective movement control.
• Calibrated digital panel meters for voltage, current, and displacement measurements.
• Supports closed-loop and open-loop testing for performance validation.

B. Robust Data Acquisition & Control System

• Integrated PC-based control with custom software for test automation and data logging.
• Graphical analysis tools for visualizing actuator performance.
• Supports remote monitoring and diagnostics for ease of maintenance.

C. Designed for Military & Aerospace Applications

• Compatible with hydraulic actuators in helicopters, fighter jets, and UAVs.
• Built with aviation-grade materials and components ensuring durability.
• Fully compliant with defence and aerospace industry standards (MIL-STD, DGQA, DGAQA, CEMILAC).

4. Technical specifications

A. Electrical System

• Input Voltage: 230V ±10%, Single-Phase, 50Hz
• Output Voltage: 0–32V DC, 10A
• Toggle Switch: SPST, 10A
• Relay: 27V, 2 Normally Open (NO), 2 Normally Closed (NC)
• UPS: 500 VA Backup

B. Hydraulic System

• Hydraulic Pressure Range: 0–3000 psi (adjustable)
• Fluid Compatibility: Aviation-grade hydraulic oil (e.g., MIL-PRF-83282, MIL-PRF-5606)
• Flow Rate Control: Variable control valves for precise adjustment
• Leakage Detection: High-sensitivity sensors for internal/external leak measurement

C. Instrumentation & Measurement

• Digital Voltmeter (with Calibration Certificate): 0–50 VDC (Accuracy: ±0.1%)
• Milliammeter Indicator: 0–1000mA DC (Accuracy: ±0.1%)
• Displacement Sensor: 0–500 mm (LVDT-based)
• Pressure Sensor: 0–3000 psi (Accuracy: ±1% Full Scale)

D. Data Processing & Display

• Monitor: 15″ TFT Display
• PC: Pentium 4 (Upgradeable to Core i5/i7)
• Printer: DeskJet for test reports

5. Applications

The MRA Test Rig is ideal for:

• Military Aviation: testing actuators of combat helicopters like LCH, Apache, Mi-17, ALH, and Chinook.
• Commercial Aviation: maintenance and testing of rotor actuators in civilian helicopters.
• R&D and Manufacturing: actuator validation for new aircraft development projects.
• MRO (Maintenance, Repair, Overhaul) Facilities: ensuring actuator reliability in aerospace service centers.

6. Compliance & certifications

The MRA Test Rig is designed in accordance with:

• ISO 9001:2015 – Quality Management System
• ISO 45001:2018 – Occupational Health & Safety
• ISO 14001:2015 – Environmental Management System
• MIL-STD-810G – Environmental testing for military equipment
• DGAQA / DGQA / CEMILAC / DRDO standards for Indian defence applications

Technical specifications at a glance

Why choose Neometrix

• 20+ years of experience in defence and aerospace engineering.
• Global clientele, including Indian Air Force, HAL, ISRO, and international defence contractors.
• End-to-end support, from design & manufacturing to installation, training, and after-sales service.
• Customization available to meet specific client requirements.

Conclusion

Neometrix's Main Rotor Actuator Test Rig delivers precise, repeatable qualification data for rotorcraft flight-control actuators. By combining proven hydraulic test methods with PC-based data acquisition and aviation-grade instrumentation, it ensures optimal actuator performance for enhanced flight control, stability, and mission readiness.