Pressure Cycle Test System

About

Our Pressure Cycling Test Rig is a high-precision, fully automated testing system designed to evaluate the fatigue behavior of fuel and hydraulic system components under cyclic pressure conditions. Engineered with dual pressure outputs (0-2000 psi & 0-500 psi), real-time monitoring, and advanced safety features, it ensures reliable, repeatable, and contamination-free testing.
Used across aerospace, defense, automotive, and industrial sectors, this state-of-the-art test rig meets international safety and performance standards.
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Technical Details

  • Insulation Ceramic paper,size:1 mtr X 0.5 mtr, 6mm thick
  • Heating Oven 2.5 m X 1.5 m X 1.5 m, Max Temp. 150 Deg C, 6 Thermostat PID Controlled
  • Testing Chamber 1.5 m X 1.2 m X 1.1 m, Front door with Toughned Glass window 0.7m X 0.7m
  • Flexible Hose SS Corrugated 1/4" X 1.2m, 150 Degree C medium tempreture WP 6 Bar
  • Flexible Hose 1/4" X 1.2m, 150 Degree C medium tempreture WP 100 Bar
  • Hose Plugs 1/4" BSP Hose Fitting Plugs
  • Electronic Air pressure Regulator Input- 4-20 mA , output -0-8 bar
  • Air Filter Unit 0-8 Bar, 1/4 End Fittings
  • DAQ Panel 600 (W) X 350 (H) X 310 (D), Enclosure
  • Cut Out As Per Drawing
  • 1.Hydraulic
  • 2.Valve Testing
  • Key Features

    • Safety Relief valves will be installed in the circuit to prevent any undesired surge in pressure
    • Temperature will be software controlled and safety limits will be defined such that temperature does not exceed the max value.
    • Testing Chamber window will be made of burst proof glass.
    • All high temperature pressure line will be properly insulated such that no high temperature surface is exposed to atmosphere.
    • Separate Emergency buttons will be present on panel for Radiator & Condenser Unit for emergency shutdown of unit.

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    Details

    Pressure Cycling Test Rig is a high-precision, fully automated testing system designed to evaluate the fatigue behavior of fuel and hydraulic system components under cyclic pressure conditions. Engineered with dual pressure outputs (0-2000 psi & 0-500 psi), real-time monitoring, and advanced safety features, it ensures reliable, repeatable, and contamination-free testing. Used across aerospace, defense, automotive, and industrial sectors, this state-of-the-art test rig meets international safety and performance standards.
    
    The Pressure Cycling Test Rig is a high-precision, fully automated testing system designed to simulate cyclic pressure variations in fuel and hydraulic systems. This state-of-the-art test rig ensures that critical components such as fuel lines, valves, pumps, and other system parts can endure varying pressure conditions without failure.
    
    Designed for aerospace, defense, automotive, rail, marine, oil & gas, and industrial applications, our test rig meets international performance and safety standards, ensuring reliable and repeatable testing. With dual pressure outputs, customizable cycle rates, real-time monitoring, and advanced safety features, our Pressure Cycling Test Rig is the perfect solution for research & development laboratories, component manufacturers, and quality control departments.
    
    Key Features & Benefits
     Dual Pressure Output – Simultaneously generates:
     • High pressure: 0-2000 psi (138 bar)
     • Low pressure: 0-500 psi (34 bar)
    
    Customizable Testing Cycles – Adjustable cycle rate from 1 to 10 cycles per minute, with a total capacity of 100,000 cycles.
    Real-Time Data Acquisition & Monitoring – Advanced data logging system with graphical visualization and reporting.
    Contamination-Free Testing –
     • 6-micron absolute pressure line filtration
     • 10-micron nominal return line filtration
     • Explosion-proof filtration system with clogging indicators
    
    Precise Temperature Control – Maintains fuel operating temperature between 15°C to 35°C, using a heat exchanger and chilled water support.
    
    Advanced Safety Mechanisms –
     • Emergency shutdown for overpressure, overheating, and low fuel level
     • Automatic system diagnostics with fault detection & alerts
     • Pressure relief valves to prevent overpressure incidents
    
    User-Friendly Interface – Touchscreen control panel with intuitive software for automated operation & remote monitoring.
    Modular & Mobile Design –
     • Mounted on wheels for easy relocation
     • Scalable and customizable for different testing needs
    
    Built for Durability & Long-Term Performance –
     • Constructed with high-grade stainless steel (SS-304) for corrosion resistance
     • Uses globally recognized brands for pumps, motors, and sensors
    
    Compliance with International Testing Standards – Meets the requirements of:
     • ISO 9001, AS9100, MIL-STD, ASTM, and SAE standards
    
    Industries That Use Our Pressure Cycling Test Rig
    1. Aerospace & Aviation
    Used by OEMs, MROs, and R&D labs to test aircraft fuel system components, such as:
     • Fuel valves, pumps, and regulators
     • Fuel injection systems
     • Hydraulic actuators and pipelines
    
    2. Defense & Military
    Ensures fuel and hydraulic system reliability for:
     • Fighter jets, helicopters, UAVs, and military vehicles
     • Naval vessels and submarines
     • Weapon systems with hydraulic actuators
    
    3. Automotive & Transportation
    Essential for engine and transmission systems in:
     • Passenger cars, heavy-duty trucks, and EVs
     • Railway locomotives and metro trains
     • Fuel injection and hydraulic braking systems
    
    4. Oil & Gas Industry
    Verifies pressure-sensitive equipment performance under cyclic stress:
     • Pipeline valves, pumps, and actuators
     • Offshore drilling equipment
    
    5. Energy & Power Generation
    Ensures reliability of hydraulic components in:
     • Gas & steam turbines
     • Renewable energy applications (wind, hydro, solar power plants)
    
    6. Medical Equipment & Life Sciences
    Used for medical-grade pressure testing in:
     • Infusion pumps and hydraulic medical devices
     • Life support and critical care systems
    
    7. Marine & Shipbuilding
    Simulates cyclic pressure variations for:
     • Fuel supply systems in ships & submarines
     • Naval defense hydraulic mechanisms
    
    8. Research & Development
    Supports prototype testing and new material evaluation in:
     • Defense, aerospace, and industrial laboratories
     • Academic institutions
    
    Technical Specifications
    1. Hydraulic Power Pack System
     • Tank: 200-liter SS-304 reservoir with fluid level indicator & temperature controller
     • Pump & Motor: Explosion-proof gear pump (2000 PSI, 300 GPH), 7.5 kW motor
     • Bladder Accumulator: Absorbs excess pressure to minimize pressure fluctuations
     • Heat Exchanger: Maintains operating temperature between 15°C - 35°C
    
    2. Filtration System
     • Suction Strainer & Pressure Line Filter
     • Non-bypass explosion-proof filters with clogging indicators
    
    3. Measurement & Control System
     • Digital Pressure Indicator: 0-3000 PSI gauge with ±0.25% accuracy
     • RTD-Based Temperature Monitoring
     • Solenoid-Operated DC Valves for precise fluid control
     • Adjustable Cycle Rate with Omron Digital Counters
    
    4. Safety Features & Interlocks
    Automatic Shutoff Conditions:
     • Motor overload or high temperature
     • Overpressure detection
     • Phase failure protection
    
    Emergency Stop Button – Instant system shutdown for operator safety
    Quick Disconnect Couplings (QCDC) with NRVs – Prevents fluid spillage & contamination
    
    System Assembly & Testing
    ✔ Assembled with precision-engineered components ✔ Each unit undergoes 100% quality testing ✔ Performance validation for cycle accuracy & emergency shutdowns ✔ Compliance with all relevant industry standards
    
    Why Choose Our Pressure Cycling Test Rig?
    Unparalleled Reliability – Low-maintenance, durable design with easy component access. Superior Safety – Equipped with advanced interlocks and contamination-free fluid handling. Comprehensive Support – We provide 24/7 client support, installation, training, and after-sales service for up to 10 years.
    Compliance & Warranty – Meets ISO, ASTM, and MIL standards. Comes with a 12-month warranty and lifetime servicing options.
    

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