Modified Test Rig for NSH-39M

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Technical Details

Specifications

The Modified Test Rig is segmented into the following subsystems:
  1. Electric Drive & Control System
  2. Main Hydraulic Circuit & Control Panel
  3. Lubrication System
  4. Data Acquisition & Control System (DAS)
Each subsystem is meticulously integrated to deliver high-performance testing of NSH-39M pumps under simulated flight conditions.

1. Electric Drive & Control System
This subsystem replicates the pump’s operating environment by providing variable torque and speed control:
 • Induction Motor: ABB, 28 kW, 3000 RPM, squirrel cage, foot-mounted, IP55 enclosure, F-class insulation
 • Variable Frequency Drive (VFD): ABB ACS800 with digital feedback control, ±1% speed accuracy
 • Encoder Feedback: Hubner OG9 rotary encoder for real-time RPM measurement
 • Starter Panel: Star-Delta panel (NXA0726) integrated with overload protection and safety interlocks
The integration ensures precise torque delivery, reduced starting current, and real-time motor diagnostics.

2. Main Hydraulic Circuit & Control Panel
This is the core functional subsystem where real-time pump testing is conducted:
 • Max Pressure: Rated for continuous duty at 250 Kg/cm2
 • Relief Manifold: REXROTH valves at preset thresholds (10, 40, 75, 90 Kg/cm2) with solenoid control
 • Reservoir: 50L (refurbished), includes:
   o Hydroline SC3-010-74 suction strainer (149 microns)
   o Hydroline FSB-25 breather
   o Shridhan SDN102 low-level switch
   o Honeywell L6188A2002 temperature switch
   o WIKA RTD-PT-100 temperature transmitter
   o WIKA R5502 dial-type temp gauge (0–100°C)
 • Flow Monitoring: Rockwin turbine flow meter (0–90 LPM, accuracy ±1%)
 • Pressure Monitoring:
   o WIKA Gauges (0–2 and 0–150 Kg/cm2, Panel mounted)
   o WIKA S-10 Pressure Transmitters (4–20mA)
 • Heat Management:
   o Alfa Laval plate-type heat exchanger (20 kW capacity)
   o Electrically actuated Parker PM-143 valves for coolant water
 • Other Features:
   o Polyhydron 300-bar hand pump with integrated relief valve
   o Static pressure test tank with automatic oil top-up
   o Close-loop cooling & filtration loop with clogging indicators
   o SS316 piping, Ham-let fittings, Sandvik tubes, and a removable drip tray for oil collection
The hydraulic layout is tailored for modular maintenance and safety-focused operation.

3. Lubrication System
Critical for ensuring mechanical reliability during test runs, the lubrication system includes:
 • Refurbished oil tank with breather (FSB-25) and suction strainer (SC3-010-74)
 • WIKA 0–16 Kg/cm2 gauge and S-10 transmitter
 • Waree differential pressure clogging indicator (2.5 bar setpoint)
 • Additional inline filtration
 • Electrical junction box (BCH) for all lubrication-related sensors
This system sustains thermal and pressure stability of the coupling between motor and pump.

4. Data Acquisition & Control System (DAS)
Enables real-time monitoring, logging, and automation:
 • DAQ Hardware:
   o NI PCI 6515 & NI PCI 6221 cards
   o Advantech/ADLINK i7 industrial PC with 19” TFT display
   o Standby PC (HP/Dell/Lenovo)
   o UPS (APC, 1000 VA), LaserJet Color Printer
   o Signal Conditioning Modules
 • Software:
   o Developed in LabVIEW with icon-based GUI
   o Functional Modes: Auto, Manual, Test, Maintenance, Calibration
   o Sensor calibration via in-situ ports
   o Test data visualization, archival, and report generation
The interface offers advanced diagnostics, test automation, and seamless shift to manual override in case of system failure.

Applications

• NSH-39M Gear Pump functionality testing
• Aerospace MRO and overhaul facilities
• Defense maintenance depots (IAF/HAL/DRDO)
• Educational and training institutions for hydraulics

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Details

INTRODUCTION
The Modified Test Rig for NSH-39M is a sophisticated, fully automated and manually operable testing platform specifically engineered for the performance evaluation, endurance testing, and diagnostic verification of aviation gear pumps, particularly the NSH-39M series. Designed with inputs from 3-BRD, Chandigarh, and developed by Neometrix Engineering Pvt. Ltd., a leader in aviation and defense-grade test systems, the rig exemplifies engineering excellence, compliance, and user-centric design. This platform offers modular integration of hydraulic, electrical, electronic, and software systems, built for rugged performance in demanding maintenance and repair environments. Its seamless shift between automatic and manual operation ensures fail-safe testing and complete operational redundancy.

What is NSH-39M?
The NSH-39M is a precision gear-type hydraulic pump widely used in Soviet-era and modern Indian military aircraft for powering hydraulic control circuits. It is essential to the operation of components like landing gears, flight control actuators, and braking systems.

Key Specifications and Characteristics:
 • Pump Type: External gear pump
 • Application: Integral to aircraft hydraulic systems
 • Working Fluid: OM-15 mineral-based hydraulic oil, aviation grade
 • Rated Operating Pressure: Up to 250 Kg/cm2
 • Flow Rate: Generally within 0–50 LPM depending on operating conditions
 • Drive Input: Originally configured for 230V DC motors at 3000 RPM; currently tested via AC induction motors for enhanced control
 • Functionality: Supplies hydraulic energy to key flight systems; requires precise calibration and maintenance
Regular performance validation and leakage monitoring are critical to maintaining mission-readiness. The NSH-39M gear pump is subjected to strict acceptance testing, best performed through a test rig like the one detailed in this description.

System Overview
The Modified Test Rig is segmented into the following subsystems:
  1. Electric Drive & Control System
  2. Main Hydraulic Circuit & Control Panel
  3. Lubrication System
  4. Data Acquisition & Control System (DAS)
Each subsystem is meticulously integrated to deliver high-performance testing of NSH-39M pumps under simulated flight conditions.

1. Electric Drive & Control System
This subsystem replicates the pump’s operating environment by providing variable torque and speed control:
 • Induction Motor: ABB, 28 kW, 3000 RPM, squirrel cage, foot-mounted, IP55 enclosure, F-class insulation
 • Variable Frequency Drive (VFD): ABB ACS800 with digital feedback control, ±1% speed accuracy
 • Encoder Feedback: Hubner OG9 rotary encoder for real-time RPM measurement
 • Starter Panel: Star-Delta panel (NXA0726) integrated with overload protection and safety interlocks
The integration ensures precise torque delivery, reduced starting current, and real-time motor diagnostics.

2. Main Hydraulic Circuit & Control Panel
This is the core functional subsystem where real-time pump testing is conducted:
 • Max Pressure: Rated for continuous duty at 250 Kg/cm2
 • Relief Manifold: REXROTH valves at preset thresholds (10, 40, 75, 90 Kg/cm2) with solenoid control
 • Reservoir: 50L (refurbished), includes:
   o Hydroline SC3-010-74 suction strainer (149 microns)
   o Hydroline FSB-25 breather
   o Shridhan SDN102 low-level switch
   o Honeywell L6188A2002 temperature switch
   o WIKA RTD-PT-100 temperature transmitter
   o WIKA R5502 dial-type temp gauge (0–100°C)
 • Flow Monitoring: Rockwin turbine flow meter (0–90 LPM, accuracy ±1%)
 • Pressure Monitoring:
   o WIKA Gauges (0–2 and 0–150 Kg/cm2, Panel mounted)
   o WIKA S-10 Pressure Transmitters (4–20mA)
 • Heat Management:
   o Alfa Laval plate-type heat exchanger (20 kW capacity)
   o Electrically actuated Parker PM-143 valves for coolant water
 • Other Features:
   o Polyhydron 300-bar hand pump with integrated relief valve
   o Static pressure test tank with automatic oil top-up
   o Close-loop cooling & filtration loop with clogging indicators
   o SS316 piping, Ham-let fittings, Sandvik tubes, and a removable drip tray for oil collection
The hydraulic layout is tailored for modular maintenance and safety-focused operation.

3. Lubrication System
Critical for ensuring mechanical reliability during test runs, the lubrication system includes:
 • Refurbished oil tank with breather (FSB-25) and suction strainer (SC3-010-74)
 • WIKA 0–16 Kg/cm2 gauge and S-10 transmitter
 • Waree differential pressure clogging indicator (2.5 bar setpoint)
 • Additional inline filtration
 • Electrical junction box (BCH) for all lubrication-related sensors
This system sustains thermal and pressure stability of the coupling between motor and pump.

4. Data Acquisition & Control System (DAS)
Enables real-time monitoring, logging, and automation:
 • DAQ Hardware:
   o NI PCI 6515 & NI PCI 6221 cards
   o Advantech/ADLINK i7 industrial PC with 19” TFT display
   o Standby PC (HP/Dell/Lenovo)
   o UPS (APC, 1000 VA), LaserJet Color Printer
   o Signal Conditioning Modules
 • Software:
   o Developed in LabVIEW with icon-based GUI
   o Functional Modes: Auto, Manual, Test, Maintenance, Calibration
   o Sensor calibration via in-situ ports
   o Test data visualization, archival, and report generation
The interface offers advanced diagnostics, test automation, and seamless shift to manual override in case of system failure.

Safety Interlocks & Features
 • Auto shutdown on low oil, high temp, filter clogging, closed suction
 • Emergency Stop Push Button
 • Visual status indicators and audio alarms
 • Protective splash guard and internal panel lighting
 • Operator guidance during error conditions via software alerts

Calibration
 • NABL-certified calibration for all sensors and instruments
 • Built-in test ports for pressure, flow, and temperature verification
 • Annual calibration schedule and toolkit provided

Documentation & Training
Neometrix ensures seamless operation with comprehensive technical deliverables:
 • Installation and operations manual
 • Wiring, hydraulic, and circuit diagrams
 • Spare parts catalogue
 • Maintenance & calibration schedule
 • On-site training for operators and technical support staff

Warranty & Support
 • Warranty: 12 months from commissioning
 • AMC: Optional 2-year Annual Maintenance Contract post-warranty
 • Support: Nationwide support with on-site intervention, spares, and remote diagnostics

Applications
 • NSH-39M Gear Pump functionality testing
 • Aerospace MRO and overhaul facilities
 • Defense maintenance depots (IAF/HAL/DRDO)
 • Educational and training institutions for hydraulics

Conclusion
The Modified NSH-39M Test Rig by Neometrix is a flagship diagnostic and evaluation solution tailored for the defense aviation ecosystem. It integrates top-tier automation, high-fidelity data acquisition, and robust hydraulic control into a user-safe and reliable platform, supporting the operational readiness of mission-critical aircraft.