Automated hydraulic component testing, to 350 bar.

Introduction

The Universal Hydraulic Test Rig from Neometrix Engineering is a turnkey, laboratory-grade platform engineered to replicate real-world hydraulic service conditions for comprehensive evaluation of pumps, motors, valves, cylinders and check valves. Leveraging over two decades of specialised design and manufacturing expertise, this rig reproduces precise pressure, flow, temperature and dynamic transients to validate performance metrics such as volumetric efficiency, leakage rates, response times and mechanical integrity, and generates certification-ready data sets for R&D, quality assurance and predictive maintenance.

Key features

• Multi-component testing: Supports pumps (piston, gear, vane), motors, valves NG6–NG32, cylinders to 4.6 m, and check valves.
• High-pressure & high-flow capability: Dual 250 kW pumps deliver up to 350 bar at 600 LPM, plus a 5.5 kW cooling pump at 250 LPM @ 10 bar.
• Precision filtration & cooling: Duplex/simplex β ≥ 200 filters and SS-304 plate heat exchangers maintain ISO 4406 cleanliness and ±2°C stability.
• Automated control suite: Siemens S7-1500 PLC with Comfort Panel HMI and pre-loaded recipes enable fully automated testing and logging.
• Modular test-bed design: Three independent stations share a common reservoir; each has its own control panel and emergency stop.
• Comprehensive safety & compliance: Emergency stops, over-temp/overflow sensors and guards meet ISO 12100 and relevant DIN/BS standards.

Construction & materials

• Corrosion resistance: All wetted parts — tank, piping, tubes, fittings — are SS-304 stainless steel.
• Precision machining: Pump manifolds and valve bodies from dual-certified stainless alloys; leak-tight assemblies.
• Structural integrity: Mild-steel skid with anti-corrosion epoxy coating; rubber isolators for vibration damping.
• Standard compliance: Pressure parts to DIN 24342 / ISO 6162; instrumentation to ISO 4406 cleanliness codes.

Test bench configuration & automation

Pump station

VFD control (vector mode) for 300–1450 RPM; quick-change displacement manifolds.

Cylinder station

Servo displacement meter; stroke-position encoders for multi-position leakage and cushioning tests.

Valve station

Conversion plates for NG-series mounting; integrated flow meters and transducers for dynamic tests.

Automation suite

Siemens S7-1500 PLC, Profinet I/O; Comfort Panel touchscreen for test setup, execution and safety interlocks. Test recipes save, clone and export; automatic data logging and report generation.

Testing capabilities & parameters

1. Hydraulic pump tests

Performance mapping: P–Q, P–η and power curves across 300–1450 RPM. Hydrostatic integrity: internal leakage and burst testing up to 400 bar.

2. Hydraulic motor tests

Torque-speed: torque vs. speed under variable load. Start-up diagnostics: stall/break-away torque; inrush current profiling.

3. Valve tests

Functional & leakage: up to 315 bar; response times <20 ms; flow vs. command ±1%. Dynamic characterization: step response, null bias, hysteresis and fail-safe conditions.

4. Cylinder tests

Multi-position leakage: rod-end, cap-end, intermediate strokes with 0.1 mm resolution. Endurance cycling: up to 1,000 cycles/hour at 315 bar, 180 LPM.

5. Check valve tests

Cracking pressure: ±1 bar accuracy. Reverse-flow leakage: ≤0.5% of rated flow at 90% cracking pressure.

Optional & customisable features

The Universal Hydraulic Test Rig can be tailored to specific client requirements across several categories:

• Automation and digital control upgrades
• Safety enhancements
• Specialized tooling for non-standard components
• Enhanced hydraulic systems (higher pressure/flow variants)
• Load management features
• Process-specific customization
• Quality control add-ons
• Mobility and scalability options
• Cooling and waste management upgrades
• Special application features

Technical specifications

Applications

• R&D & qualification: Characterize new hydraulic designs under simulated extreme loads and temperatures; generate certification reports.
• Production quality control: Batch testing to verify tolerance compliance and detect early failures; reduce cycle times with automated acceptance routines.
• Maintenance & overhaul: Condition-based diagnostics for internal wear and performance drift; endurance cycling for recertified components.
• Education & training: Hands-on fluid-power experiments covering efficiency mapping, dynamic response and failure analysis.

Conclusion

The Neometrix Universal Hydraulic Test Rig sets a new industry benchmark by fusing rugged SS-304 construction, high-precision instrumentation and an advanced automation suite. From prototype R&D and OEM production lines to maintenance workshops and academic labs, it delivers exhaustive test coverage, repeatable results and full data traceability. Safety-certified and built with global-standard components, this rig ensures reliability, simplifies spares management and accelerates time-to-market — ultimately enhancing hydraulic component quality, reducing downtime and driving innovation across diverse fluid-power applications.

Enhance your hydraulic testing capabilities by integrating this system with our Hydraulic Control Valve Test Bench, designed for precise performance evaluation of directional, pressure, and flow control valves under dynamic conditions.

For applications requiring cyclic durability and fatigue analysis, the Pressure Cycle Test System provides reliable long-term pressure fluctuation testing to validate component life and structural integrity.

In advanced valve diagnostics and calibration environments, our CV and Control Valve Test Rig enables accurate characterization of flow coefficients and control behavior across varying operating parameters.

Additionally, for comprehensive valve performance validation, the Valve Test Rig complements this system by supporting leakage testing, pressure holding, and functional verification across multiple valve types. These integrated solutions ensure a complete hydraulic testing ecosystem, improving accuracy, reliability, and compliance with industry standards.