Manual Loading Rig / 280 kgf/cm² · 45 LPM / NAS 1638 Class 4 / India

MLR · ACTUATOR LOAD BENCH

Manual Loading Rig, rated to 30,000 kgf at 280 kgf/cm².

A high-precision electro-hydraulic test bench for validating multi-channel aircraft actuators under realistic load. A 25 HP axial-piston pump feeds 45 LPM from a 60 L SS-304 reservoir, while a 30,000 kgf load cell, 250 mm LVDTs and a PC-based NI DAQ running a custom LabVIEW interface capture force, displacement, speed and sealing performance in one continuous test sequence.

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Manual loading rig - structural and component static load application and force measurement test frame for defence and aerospace testing by Neometrix

Fig · 01 Manual Loading Rig · hydraulic power pack, loading frame and dual control panel

Built and verified to:

NAS 1638 Class 4

Max Pressure

280kgf/cm²

Pump Flow

45lpm

Load Cell

30kkgf

Stroke Range

250mm

Speed

380mm/s

Overview

Real load, on the bench.

The Neometrix 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.

Manual loading rig product view - hand-operated structural load frame and force measurement system for component qualification testing by Neometrix

Fig · 02 Loading frame with constant-load and position-load cylinders, load cell and LVDT in line

The rig simulates real-world mechanical load conditions, enabling comprehensive force, displacement and leak tests on a single bench. It combines rugged mechanical construction with sophisticated instrumentation and software-driven automation to deliver precise, repeatable results run after run.

A 60 L SS-304 reservoir feeds a 25 HP axial-piston pump delivering 45 L/min at up to 280 kgf/cm². Triple-stage filtration with automatic clog detection holds cleanliness at NAS 1638 Class 4 or better, and an Alfa Laval water-cooled heat exchanger keeps fluid temperature between 25–40 °C for the whole test window.

Force, stroke, speed and seal — measured on one bench.

Instrumentation includes a 30,000 kgf load cell, 250 mm LVDT displacement sensors, digital pressure and temperature transducers, and a PC-based NI DAQ system running a custom LabVIEW interface for real-time monitoring, data logging and automated report generation. Built-in safety interlocks protect against low oil level, filter ΔP, over-temperature and phase failure, while a structured maintenance schedule keeps the rig on-spec across its service life.

Architecture

Six subsystems, one test bench.

Hydraulics, thermal conditioning, filtration, instrumentation, control and safety are integrated into a single dual-panel electro-hydraulic test bench.

Sub · 01

Hydraulic Power Pack

25 HP axial-piston pump delivering 45 LPM at 250 kgf/cm² from a 60 L SS-304 tank running AMG-10 or AMG-10B fluid; SS-braided Teflon hoses rated to 220 bar.

Sub · 02

Triple-Stage Filtration

Pall inline filters with 20 µm, 10 µm and 5 µm elements and electrical clog indicators hold NAS 1638 Class 4 cleanliness, with shutdown interlocks on filter ΔP.

Sub · 03

Thermal Management

Alfa Laval water-cooled heat exchanger fed with 20 LPM chilled water at 20 °C maintains hydraulic fluid within the 25–40 °C operational range.

Sub · 04

Loading Cylinders

Two cylinder types — constant load and position load — apply controlled mechanical load to the actuator under test up to a measurable output force of 24,000 kgf.

Sub · 05

Measurement & DAQ

Honeywell load cell to 30,000 kgf, Ceresco LVDTs (250 mm, 0.01% accuracy), digital pressure and temperature transducers, and NI DAQ cards under a custom LabVIEW GUI.

Sub · 06

Control Panel & Safety

Dual hydraulic and electrical panels with two DROs, digital timer, particle counter, LED-indicated motor and valve controls, and an emergency stop pushbutton.

Test Capabilities

Five protocols. Full actuator validation.

As a multi-channel power drive tester, the rig covers force, kinematic, sealing and functional validation of electro-hydraulic actuators in one continuous programme.

T · 01

Linear Force Output

Load cell measurement of actuator output force against commanded load, up to a maximum measurable output force of 24,000 kgf.

Up to 24,000 kgf

T · 02

Displacement & Stroke

LVDT-based verification of stroke behaviour and travel repeatability across a 250 mm range at 0.01% accuracy.

250 mm · 0.01%

T · 03

Speed Control Testing

Measurement of the actuator output link speed under load, with speed measurement capability up to 380 mm/sec.

Up to 380 mm/sec

T · 04

Leak Testing

Sealing performance verification under pressure, with digital pressure transducers and gauges monitoring the circuit throughout the hold.

Sealing Performance

T · 05

SPM Operational Verification

Functional checks of special-purpose machine operation alongside multi-channel actuator sequencing for production and R&D sign-off.

Production QC & R&D

Image Gallery

The rig, on the shop floor.

Component detail from a delivered Manual Loading Rig — loading frame, load cell and instrumentation assembly.

Manual loading rig component and load cell detail - structural static force application and measurement system by Neometrix

Manual loading rig hydraulic loading cylinder and actuator mounting detail for multi-channel aircraft actuator testing by Neometrix

Manual loading rig control panel and instrumentation readout detail with digital displays for electro-hydraulic actuator test bench by Neometrix

Fig · 03–05 Loading frame and force measurement (left) · loading cylinder and mounting (centre) · control panel and readouts (right)

Specifications

Full technical parameters.

Key system parameters for the standard Neometrix Manual Loading Rig configuration.

Working Fluid	AMG-10 or AMG-10B
Volume Tank	60 litres (SS-304)
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
Pump & Motor	25 HP axial-piston pump
Filtration	Pall inline filters, 20 µm / 10 µm / 5 µm with clog indicators
Power Supply	3-phase, 415 V AC, 50 Hz
Cooling Requirement	Chilled water, 30 LPM @ 20 °C
Operating Fluid Temperature	25–40 °C
Max Measurable Output Force	24,000 kgf
Cylinders	2 types (constant load & position load)
Load Cell	Honeywell, up to 30,000 kgf
Displacement Range	250 mm (0.01% accuracy)
Speed Measurement	Up to 380 mm/sec
Hoses	SS-braided Teflon, 220 bar rating
Data Acquisition	PC-based NI DAQ cards with custom LabVIEW GUI
Reporting	Data logging with HTML report generation
Safety Interlocks	Low oil level, filter ΔP, over-temperature, phase failure, motor overload, E-stop

Applications

Where it runs.

From actuator R&D through production QC to depot-level validation, the Manual Loading Rig serves the full lifecycle of electro-hydraulic actuators.

A · 01Performance testing of multi-channel aircraft actuators

A · 02Verification of linear force output, displacement and stroke behaviour

A · 03Speed control testing of the actuator’s output link

A · 04Leak testing and SPM operational verification

A · 05Defence, aerospace and R&D applications using electro-hydraulic actuators

A · 06Production quality control and depot-level actuator re-validation

In Depth

The complete technical read.

Engineering narrative for test engineers, procurement teams and QA managers who want the full picture before committing to a test programme.

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 (20 µm, 10 µm, 5 µm) 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 behaviour.
Speed control testing of the actuator’s output link.
Leak testing and SPM operational verification.
Defence, 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 litres (SS-304).
Pump: 25 HP axial-piston pump, 45 LPM @ 250 kgf/cm².
Filters: Pall inline filters with 8 µm, 5 µm and 20 µm 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.
Two 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 litres
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, 415 V 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

Maintenance schedule

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 and relief valve.

Safety measures

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

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.

Conclusion

The Manual Loading Rig embodies a robust and versatile solution for the rigorous testing of multi-channel electro-hydraulic actuators in aerospace and defence 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.

FAQ

Common questions.

Plain-language answers from the engineering team.

Q · 01 What is the Manual Loading Rig?

The Manual Loading Rig is a specialized electro-hydraulic test system built by Neometrix Engineering Pvt Ltd, India, for the performance evaluation and validation of multi-channel power drives used in aircraft systems. It simulates real-world mechanical load conditions so that force, displacement, speed and leak tests can be run on a single bench.

Q · 02 Who manufactures the Manual Loading Rig?

The Manual Loading Rig is designed and manufactured by Neometrix Engineering Pvt Ltd, a leading test equipment manufacturer and supplier based in India.

Q · 03 What pressure and flow does the Manual Loading Rig deliver?

A 25 HP axial-piston pump delivers at least 45 LPM at 250 kgf/cm², with an adjustable pressure range of 10 to 250 kgf/cm² and a maximum pressure of 280 kgf/cm². The rig runs on AMG-10 or AMG-10B hydraulic fluid from a 60 litre SS-304 reservoir.

Q · 04 How much force and displacement can the rig measure?

Force is measured by a Honeywell load cell rated up to 30,000 kgf, with a maximum measurable output force of 24,000 kgf. Displacement and speed are measured by Ceresco LVDT sensors with a 250 mm range and 0.01% accuracy, and speed measurement up to 380 mm/sec.

Q · 05 How is hydraulic cleanliness maintained on the Manual Loading Rig?

Triple-stage Pall inline filters with 20 µm, 10 µm and 5 µm elements and electrical clog indicators hold fluid cleanliness at NAS 1638 Class 4 or better. An in-line particle counter reports the achieved NAS class during operation.

Q · 06 How is oil temperature controlled during a test?

An Alfa Laval water-cooled heat exchanger supplied with chilled water at 20 °C holds the hydraulic fluid within the 25–40 °C operating band throughout long test sequences.

Q · 07 What safety interlocks are built into the Manual Loading Rig?

The rig shuts down automatically on motor overload, low oil level, clogged filter differential pressure, over-temperature and power phase failure, and carries an emergency stop pushbutton on the control panel.

Q · 08 Can the Manual Loading Rig be integrated with data acquisition systems?

Yes. The rig uses a PC-based National Instruments DAQ system with a custom LabVIEW graphical interface providing login-based access, a sensor calibration window, test selection and parameter monitoring, real-time fault indicators, and data logging with HTML report generation.

Q · 09 What industries and applications use the Manual Loading Rig?

It is used for performance testing of multi-channel aircraft actuators, verification of linear force output, displacement and stroke behaviour, speed control testing of the actuator output link, leak testing and SPM operational verification, and defence, aerospace and R&D work involving electro-hydraulic actuators.

Q · 10 How can I get a quotation for the Manual Loading Rig?

You can request a quotation for the Manual Loading Rig by contacting Neometrix Engineering Pvt Ltd through https://neometrixgroup.com/products/manual-loading-rig or by phone at +91-7777-876-876.

Get a proposal

Tell us your actuator load
and stroke requirements.

We size the loading cylinders, configure the load cell and LVDT ranges, and walk through the force, displacement, speed and leak test programme with your QA team before you commit.

Request proposal +91 7777 876 876

Manual Loading Rig, rated to 30,000 kgf at 280 kgf/cm².

Real load, on the bench.