Details

Introduction & Purpose
The Rain Water Test Rig is engineered to reproduce controlled rainfall conditions over aircraft surfaces, using a total of 82 top-mounted nozzles and 16 nozzles on each side. Its two core test phases are:
- Qualification Testing on the prototype, to validate design efficacy, safety margins, life-cycle performance and reliability against both technical and end-user requirements.
- Acceptance Testing during bulk production, to ensure every unit meets the governing specs before dispatch, thereby guaranteeing consistent quality and minimizing in-service failures.

Structural Overview
A full-size GA drawing shows the rig’s detachable twin-tank structure, support frame and mobility system:
- Water Tanks: Two 2,000 L PVC tanks sit on a detachable SS 304 support frame.
- Frame: Welded SS 304 square tubing (100 × 100 mm base; 50 × 50 mm top), providing rigidity and corrosion resistance.
- Mobility: Six heavy-duty caster wheels (7,500 N each) with locks allow easy positioning and secure fixation on the hangar floor.
- Adjustability: Side-wing assemblies pivot ±60° to vary spray angle, accommodating different fuselage geometries.

Hydraulic Circuit & Flow Path
The hydraulic schematic outlines a closed-loop water circuit:
1. Supply from the 2,000 L tanks through a 60-mesh SS 304 strainer.
2. Boost via a Grundfos CM 15-3 centrifugal pump (4 kW/5.36 HP), delivering up to 250L/min at 10 kg/cm2.
3. Main Manifold: 3′′ Schedule-80 uPVC piping distributes flow to top and side headers.
4. Branch Lines: 1′′ uPVC branches feed each SS 304 nozzle (spray capacity 1–2 L/min at 2bar).
5. Return/Drain: Drain valves allow rapid emptying post-test.

Key Features & Materials
- Comprehensive Nozzle Array:
  • Top: 82 × SS 304 sprinklers (Ø2 mm holes in 8-place pattern) ensure uniform cover.
  • Sides: 32 × SS 304 nozzles on pivoting pipes, for both horizontal and 60°-upward sprays.
- Precise Control: WIKA 232.50.100 pressure gauge (0–10 kg/cm2) for real-time monitoring; shut-off and drain valves facilitate flow regulation and safe shutdown.
- Filtration: 60-mesh filter strainer rated 250 LPM removes particulates, protecting the pump and nozzles.
- Robust Construction:
  • Piping & Fittings: Schedule-80 uPVC (1′′/2′′/3′′) with solvent-welded joints and unions for leak-proof integrity.
  • Structural Steel: SS 304 tubing resists corrosion in wet environments.
- Mobility & Setup: Lockable caster wheels and detachable frame modules allow rapid installation, detachment and transport.

Technical Specifications & Performance

  

    

      
Parameter
      
Specification
    
  
  

    

      
Overall Dimensions (L×W×H)
      
12,600 × 2,000 × 3,500 mm
    
    

      
Tank Capacity
      
2 × 2,000 L PVC
    
    

      
Pump & Motor
      
Grundfos CM 15-3, 4 kW (5.36 HP), 3-phase, 50 Hz
    
    

      
Flow Rate
      
Up to 250 LPM; per-nozzle: 1–2 LPM at 2 bar
    
    

      
Working Pressure
      
Up to 10 kg/cm²; test pressure typically 1–2 bar
    
    

      
Nozzle Material & Size
      
SS 304; Ø2 mm holes (8-place)
    
    

      
Filter Mesh Size
      
60 mesh (250 LPM capacity)
    
    

      
Frame Material
      
SS 304 square tubing
    
    

      
Piping
      
Schedule-80 uPVC
    
    

      
Mobility
      
6 × lockable caster wheels (7,500 N each)
    
    

      
Operating Voltage/Temp.
      
180–240 VAC; 15–24 °C ambient
    
    

      
Weight
      
Approximate per GA drawing
    
  


Bill of Materials & Sourcing

  

    

      
Item
      
Description & Source
    
  
  

    

      
Water Tanks
      
PVC, 2,000 L × 2 – Sintex/Supreme
    
    

      
Pump & Motor
      
Grundfos CM 15-3 assembly
    
    

      
Filter Strainer
      
Neometrix NEFILT60, SS 304, 60 mesh
    
    

      
Pressure Gauge
      
WIKA 232.50.100, 0–10 kg/cm²
    
    

      
Nozzles
      
Neometrix NENZ114 SS 304, 82 top + 32 side
    
    

      
Piping & Fittings
      
Supreme uPVC Schedule-80 (1″–3″), solvent, unions, tees, elbows
    
    

      
Caster Wheels
      
Elesa Ganter RE.F5 200-SSL-H, 750 mm height
    
  


Quality Assurance Plan (QAP)
Under Contract GEM/2023/B/3091277, every bought-out and in-house component undergoes 100% inspection:
- Certificates: COC from manufacturers, calibration records for pump/motor and filter, visual checks for piping and nozzles.
- Process Audits: Witness points for welding, painting (SA-2.5 surface prep; powder coat DFT 80–100 μm) and final assembly.
- Documentation: Test reports, compliance certificates and internal inspection reports (IIR) archived for each rig.

Factory Acceptance Test (FAT)
FAT validates performance per spec before shipment:
1. Visual Verification of dimensions, detachable halves, wheel locks, frame alignment.
2. Technical Parameters:
  • Side-wing pitch: 750 mm spacing; rotation to 60°.
  • Voltage range: 180–240 V; max pressure: 1.4 kg/cm2; flow: 2.11–3.81 mm/min measurement system compliant.
3. Leak-Proof Checks at 1–2 bar, verifying no seepage from joints or nozzles.
4. Certificate Review: All COCs, calibration and compliance docs must be on file.

Applications & Use Cases
- Aerospace Certification: Validates rain-penetration resistance of fuselage seals, canopies, panel joints and coatings per MIL-STD and FAA requirements.
- Environmental Qualification: Tests water-ingress protection of avionics bays, cargo doors and fasteners.
- Maintenance Training: Simulates rain-light conditions to verify post-repair sealing, drainage paths and water-shed performance.

Conclusion & Support
The Rain Water Test Rig delivers a turnkey, standards-compliant solution for rigorous rain-exposure testing. Its precision hydraulic layout, robust SS 304 structure, and comprehensive QA/QC make it ideal for both prototype qualification and serial acceptance.
Neometrix Engineering provides full after-sales support and spares per the QAP.