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न्युमैटिक मॉड्यूल, मॉड्यूलर न्युमैटिक टेस्ट स्टेशन, पीएलसी नियंत्रित न्युमैटिक रिग, हाई फ्लो एयर परीक्षण प्लेटफॉर्म,

Pneumatic Test Rig (Vacuum)

About

The Vacuum Test Rig is a high-precision testing platform designed to simulate altitude conditions up to 60,000 feet for the evaluation of aerospace valves and components. Featuring dual stainless-steel chambers, advanced vacuum and flow control systems, and real-time data acquisition, it enables comprehensive testing for leakage, pressure response, and flow behaviour. With integrated safety mechanisms, optional SCADA automation, and compliance with major aerospace and industrial standards, the system is ideal for manufacturers, testing labs, and MROs seeking reliable altitude simulation and performance verification.
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Technical Details

Feature Specification
Cabin Pressure Chamber Simulates pressurized internal aircraft conditions
Altitude Chamber Mimics external atmospheric conditions
Construction SS304-grade stainless steel
Volume ~0.55 ± 0.1 m³ each
• Aerospace Valve Testing: Cabin pressure regulators, ECS valves, safety relief valves, and fuel system components.
• Leakage Detection: Identify micro-leaks under altitude-induced pressure differentials.
• Flow & Pressure Characterization: Analyze behavior under dynamic flow conditions and verify regulatory compliance.
• Component Qualification: Supports endurance, response, and environmental testing for OEM validation.

Key Features

  • Altitude Simulation: Accurately replicates conditions from sea level to 60,000 feet, covering the entire operational envelope of commercial and defence aircraft.
  • Dual-Chamber Design: Includes independent cabin and altitude chambers to simulate realistic inter-compartment pressure differentials.
  • Adjustable Flow Control: Delivers flow rates from 0.3 to 20 kg/min, ideal for both low-leakage and high-throughput applications.
  • High-Precision Instrumentation: Integrated pressure transmitters, differential sensors, and digital mass flow meters from reputed brands like WIKA,Bronkhorst, and Siemens.
  • Advanced Safety Mechanisms: Equipped with pressure relief valves, interlocks, and emergency shutdown features.
  • User-Centric Interface: Digital control panel with manual overrides for intuitive operation and full process visibility.

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Details

Introduction
The Vacuum Test Rig is a precision-engineered testing platform designed for simulating high-altitude conditions in controlled environments. Developed specifically for the aerospace sector, it replicates atmospheric pressures corresponding to altitudes up to 60,000 feet (18.2 km), enabling the rigorous evaluation of aerospace valves and components. It supports critical test procedures such as leakage detection, pressure response verification, and real-time flow rate analysis. Its robust construction,
integrated safety systems, and optional automation make it an indispensable tool for aerospace OEMs, MROs, and test labs.

Key Features
 • Altitude Simulation: Accurately replicates conditions from sea level to 60,000 feet, covering the entire operational envelope of commercial and defence aircraft.
 • Dual-Chamber Design: Includes independent cabin and altitude chambers to simulate realistic inter-compartment pressure differentials.
 • Adjustable Flow Control: Delivers flow rates from 0.3 to 20 kg/min, ideal for both low-leakage and high-throughput applications.
 • High-Precision Instrumentation: Integrated pressure transmitters, differential sensors, and digital mass flow meters from reputed brands like WIKA, Bronkhorst, and Siemens.
 • Advanced Safety Mechanisms: Equipped with pressure relief valves, interlocks, and emergency shutdown features.
 • User-Centric Interface: Digital control panel with manual overrides for intuitive operation and full process visibility.

Applications
 • Aerospace Valve Testing: Cabin pressure regulators, ECS valves, safety relief valves, and fuel system components.
 • Leakage Detection: Identify micro-leaks under altitude-induced pressure differentials.
 • Flow & Pressure Characterization: Analyze behavior under dynamic flow conditions and verify regulatory compliance.
 • Component Qualification: Supports endurance, response, and environmental testing for
OEM validation.

System Components & Technical Specifications

Chambers

Feature Specification
Cabin Pressure Chamber Simulates pressurized internal aircraft conditions
Altitude Chamber Mimics external atmospheric conditions
Construction SS304-grade stainless steel
Volume ~0.55 ± 0.1 m³ each
Vacuum Generation
Component Details
Vacuum Pump High-capacity system capable of achieving 72 mBar absolute pressure
Motor 30 HP, 3-phase squirrel cage induction, 415V, 50Hz
VFD Enables precise pump control and altitude profiling
Flow & Pressure Control • Modulating Valves: Electro-pneumatically actuated for smooth flow adjustments. • Manual Valves: For isolation and safety control. • Buffer Tank: 1 ± 0.2 m3 vacuum accumulator for stable pressure control. Instrumentation • Pressure Transmitters: 0–4 Bar (abs), 0–16 Bar (gauge) • Differential Pressure Sensors: Up to 500 mBar • Manometers: Water-filled and mercury-filled • Flow Meters: Digital, real-time measurement devices Control & Monitoring • Digital Displays: Real-time pressure, flow, and vacuum readings • Manual Controls: For on-the-fly adjustments • Safety Interlocks: System disables if unsafe conditions are detected Safety Features • Pressure Relief Valves: Auto-activation to prevent overpressure conditions. • Emergency Stop: Quick system shutdown in critical situations. • Interlock Systems: Ensure safe operation and prevent unauthorized testing. Compliance & Certifications • Design Compliance: ANSI B16.5 Class #150 piping and fittings • Valve Integrity: ANSI/FCI Class IV leakage standards • Quality Assurance: Manufactured in ISO 9001, ISO 14001, ISO 45001-certified facilities Utility Requirements • Compressed Air: 12 kg/cm2 clean and dry air • Cooling Water: 45 LPM continuous flow for vacuum pump cooling • Electrical Supply: 415V, 3-phase, 50Hz • Installation Space: Sufficient room for chamber access, maintenance, and ventilation Maintenance & Support Routine Maintenance Includes: • Daily inspection of pump oil and belt tension • Cooling system check before each operation • Functional testing of safety interlocks and actuators • Sensor calibration and valve responsiveness checks Documentation Provided: • Operation & Maintenance Manual • Electrical & Pneumatic Circuit Diagrams • Assembly & Layout Drawings • Calibration Certificates • Preventive Maintenance Schedule Spare Parts Availability: • OEM parts for valves, sensors, pumps, and motors • Optional kits: pressure transmitters, actuator parts, seals, relays Technical Support: • 24x7 Remote Engineering Support • Onsite Commissioning & Training • Annual Maintenance Contracts (AMCs) • Recalibration Services Optional Integration & Automation SCADA-Based Control: • HMI/PLC/SCADA remote control & monitoring • Alarm/event logging, data trending, audit trails • Barcode/RFID integration for traceability Automated Test Sequences: • Pre-programmed altitude/pressure profiles • Fatigue and cyclic test programming • Multi-point test modes DAQ & Connectivity: • USB/Ethernet/Cloud data export • Compatible with Industrial IoT systems • SQL/CSV data logging Advantages Over Conventional Systems • Altitude Simulation Accuracy: True in-flight condition replication • Dual-Chamber Flexibility: Tests inter-compartment pressure control components • True Mass Flow Measurement: Real-time data unaffected by pressure/temp variations • Enhanced Safety: Both mechanical and electronic fail-safes • Modular & Customizable: Easily scalable for production or R&D environments Technical Summary
Parameter Specification
Altitude Range 0–60,000 ft (0–18.2 km)
Vacuum Pressure Down to 72 mBar
Flow Capacity 0.3 – 20 kg/min
Chamber Volume 0.55 ± 0.1 m³ (x2)
Vacuum Tank 1 ± 0.2 m³
Vacuum Pump 30 HP with VFD
Instrumentation Siemens, WIKA, Bronkhorst, FITZER
Power Supply 415V, 3-Phase, 50Hz
Compressed Air 12 kg/cm²
Cooling Water 45 LPM continuous
Control Interface Digital + Optional SCADA
Typical Components Tested • Cabin Pressure Regulators • Environmental Control System (ECS) Valves • Safety Relief Valves (SRVs) • Altitude Hold Valves • Interconnecting Line Valves (ILVs) • Bleed Air Modulators • Fuel Tank Inerting Valves • Emergency Venting Systems Standards & Compliance Support • MIL-STD-810: Altitude Testing • RTCA DO-160: Environmental Conditions • ASTM F37: Gasket Sealability • ISO 8573-1: Compressed Air Quality • ISO 12100 / IEC 60204-1: Machinery Safety Custom certification packages available for CE, UL, or aerospace-specific validations upon request. Ordering & Customization Each unit is built-to-spec based on your testing envelope and application. Available customization options include: • Larger or smaller chambers • Extended flow ranges • Compatibility with helium, nitrogen, or other gases • Environmental conditioning add-ons (humidity, temperature) • Integration with client-specific software or automation systems

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