Details

Introduction
The Manual Loading Rig is a specialized electro-hydraulic test system developed for the performance evaluation and validation of multi-channel power drives used in aircraft systems. This test bench simulates real-world mechanical load conditions, enabling
comprehensive force, displacement, and leak tests. It combines rugged mechanical construction with sophisticated instrumentation and software-driven automation to ensure precise and repeatable test results.

Key Features
• Multi-Channel Electro-Hydraulic Testing Capability: Designed to test complex multi-channel actuators by measuring force, displacement, speed, and sealing performance.
• Advanced Measurement System: Integrates load cells, LVDT-based displacement sensors, and digital pressure and temperature transducers.
• Industrial Grade Control System: PLC- and PC-based control with NI data acquisition cards, graphical UI, and a custom-developed software suite.
• Comprehensive Filtration System: Triple-stage inline filters (20μ, 10μ, 5μ) with electrical clog indicators and shutdown interlocks ensure hydraulic cleanliness up to NAS Class 4.
• Efficient Thermal Management: A water-cooled heat exchanger maintains fluid temperature within the operational range of 25–40°C.
• Built-In Safety Interlocks: Automatic shutdowns for motor overloads, low oil level, clogged filters, and power phase disorders.

Applications
• Performance testing of multi-channel aircraft actuators
• Verification of linear force output, displacement, and stroke behavior
• Speed control testing of the actuator’s output link
• Leak testing and SPM operational verification
• Defense, aerospace, and R&D applications where electro-hydraulic actuators are employed

System Components & Functionality
Hydraulic System:
- Hydraulic Oil: AMG-10 or equivalent
- Tank Capacity: 60 liters (SS-304)
- Pump: 25 HP axial piston pump, 45 LPM @ 250 kgf/cm2
- Filters: Pall inline filters with 8μ, 5μ, and 20μ elements and clogging sensors
- Heat Exchanger: Alfa Laval, 20 LPM chilled water at 20°C
- Hoses: SS braided Teflon with 220 Bar rating

Control Panel:
- Dual-panel layout: Hydraulic and Electrical
- 2 Digital Readouts (DROs) for temperature and flow
- Digital timer, particle counters (NAS class), and emergency stop
- Motor and valve ON/OFF push buttons with LED indicators

Measurement & Instrumentation:
- Force Measurement: Honeywell load cell, up to 30,000 kgf
- Displacement & Speed: Ceresco LVDT sensors (250 mm range, 0.01% accuracy)
- System Monitoring: Pressure gauges, flow meter, temperature sensor, and particle counter

Software Features
- Custom GUI with login-based access for operators and administrators
- Calibration window for sensor adjustment
- Test selection and parameter monitoring interface
- Real-time fault indicators
- Data logging and report generation in HTML format

Technical Specifications

  

    

      
Parameter
      
Value
    
  
  

    

      
Working Fluid
      
AMG-10 or AMG-10B
    
    

      
Volume Tank
      
60 liters
    
    

      
Cleanliness Level
      
NAS 1638 Class 4 or better
    
    

      
Pressure Adjustment Range
      
10 to 250 kgf/cm²
    
    

      
Max Pressure
      
280 kgf/cm²
    
    

      
Pumping Capacity
      
≥ 45 LPM @ 250 kgf/cm²
    
    

      
Power Supply
      
3-phase, 415V AC, 50 Hz
    
    

      
Cooling Requirement
      
Chilled water, 30 LPM @ 20 °C
    
    

      
Max Measurable Output Force
      
24,000 kgf
    
    

      
Cylinders
      
2 types (constant load & position load)
    
    

      
Load Cell
      
Up to 30,000 kgf
    
    

      
Displacement Range
      
250 mm (0.01% accuracy)
    
    

      
Speed Measurement
      
Up to 380 mm/sec
    
  



Speed Measurement Up to 380 mm/sec
• Daily/Per-Use: Visual inspection, leak check, zero pressure reset
• Monthly: Leak inspection, dust cleaning
• Quarterly: Pump performance, filter cleaning, bolt torquing
• Bi-Annually: Pressure checks, element replacement, valve calibration
• Every 5 Years: Overhaul of motor, pump, flow meter, relief valve

Safety Measures
- Low oil level cutoff
- Filter ΔP shutdown
- Over-temperature lockout
- Phase-failure detection
- Emergency stop

Conclusion
The Manual Loading Rig embodies a robust and versatile solution for the rigorous testing of multichannel electro-hydraulic actuators in aerospace and defense applications. With its precision measurement systems, advanced control architecture, comprehensive safety
interlocks, and structured maintenance protocols, it ensures reliable, repeatable, and safe operation. This rig not only meets but often exceeds industry standards for cleanliness, thermal control, and data acquisition, making it an indispensable asset for R&D, certification, and quality assurance teams.


  Advanced Actuator Test Rigs for Aerospace and Industrial Applications

  Accurate testing of actuators is critical for aerospace and industrial systems. Manual loading rigs and electro-hydraulic test benches provide controlled environments for evaluating hydraulic actuators and other force-generating components. Actuator load testers and force displacement testers ensure precise measurement of actuator performance, reliability, and compliance with design specifications.

  High-performance setups, including multi-channel power drive testers and hydraulic actuator test rigs, allow simultaneous testing of multiple parameters, enhancing efficiency and data accuracy. Specialized aerospace actuator test benches integrated with NI DAQ hydraulic rigs support advanced data acquisition and analysis, enabling engineers to monitor real-time performance under simulated operational conditions.

  These test rigs are essential for quality assurance, R&D, and certification of hydraulic and electromechanical actuators, ensuring reliability, safety, and optimal performance in critical applications.