• Production acceptance testing of aircraft aggregates to validate internal cleanliness and flow behaviour. • MRO (Maintenance, Repair & Overhaul) flushing of aggregates after disassembly and reassembly cycles. • Restoration and life-extension flushing to remove accumulated contaminants and extend aggregate service life. • Diagnostic flushing during failure investigation to detect internal clogging, flow restriction or abnormal behaviour. • Dynamic operational simulation of aggregates using controlled ATF flow, pressure, temperature and rotation. • Deep cleaning of fine-tolerance aviation components such as servo valves, hydraulic pumps and actuation units. • Removal of micro-scale contaminants (10–15 microns) that can obstruct lubrication passages and precision clearances. • Ensuring aggregates meet aviation cleanliness standards before installation, dispatch or certification.
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1. Introduction Modern aircraft aggregates—whether they belong to engine modules, airframe actuation systems, or auxiliary hydraulic units—are built with extremely fine tolerances, slender pressure passages, and micro-scale lubrication galleries. Even a 10–15 micron particle, if lodged within a servo-valve spool clearance or a lubrication nozzle, can lead to catastrophic failure. Contamination is one of the largest root causes of premature aggregate wear, erratic flow behaviour, thermal instability, and system malfunction. In a flight environment, where pressures can reach hundreds of bars and components cycle thousands of times per hour, the impact of contamination becomes exponentially more dangerous. This is why every aggregate—whether new, overhauled, or under qualification—must undergo a rigorous flushing process before being passed as airworthy. The Aircraft Aggregate Flushing Rig by Neometrix Defence Limited has been engineered specifically to perform deep and dynamic internal cleaning of these aggregates. Unlike simple wash or solvent-based cleaning, this machine replicates actual operational behaviour by circulating ATF through the aggregate at controlled pressures, temperatures, and flow rates while simultaneously driving or actuating the unit. This ensures contaminants are removed from even the most recessed internal cavities—zones that cannot be accessed by static cleaning methods. The equipment plays a critical role in multiple phases of aerospace operations: • Production Acceptance: Ensures newly manufactured aggregates meet cleanliness & performance criteria. • Maintenance, Repair, Overhaul (MRO): Removes accumulated debris after disassembly-reassembly cycles. • Life Extension / Refurbishment: Restores internal cleanliness for long-term operational reliability. • Failure Investigation / Diagnostics: Helps identify flow restrictions, internal clogging, or behaviour anomalies. Ultimately, the system becomes a primary defence against flow-induced failures, hydraulic instability, and safety hazards. Its combination of hydraulic, pneumatic, mechanical, and electronic subsystems makes it a cornerstone of any aerospace MRO or production environment. 2. System Architecture Overview The equipment consists of multiple integrated modules designed to ensure robust, repeatable, and aviation-grade flushing performance. Each module works cohesively to simulate real-world aggregate operation. Major Subsystems: • Multi-stage Hydraulic Flushing Circuit • ATF Storage, Transfer & Filtration System • Pneumatic Supply Circuit • Drive & Loading Unit for Aggregate Rotation/Actuation • Sink, Drain & Return Recovery System • Electrical Control & Monitoring Panel • Structural Frame, Mounting, and Interconnecting Hardware Together, these create a high-integrity flushing platform capable of removing contaminants, validating internal flow profiles, and ensuring readiness for aviation use. 3. Detailed System Description 3.1 Hydraulic Circuit The hydraulic circuit is the central element of the rig, responsible for delivering controlled ATF flow and pressure into the aggregate under test. It is designed to mimic service conditions and eliminate internal contamination. Functional Capabilities: • Dual pressure supply: 25 kgf/cm2 and 10 kgf/cm2 • Precise flow regulation through adjustable bypass circuits • Closed-loop ATF circulation with multi-stage filtration • Ability to flush multiple aggregate types via dedicated output lines • Real-time pressure monitoring for safety and verification Hydraulic Flow Path Breakdown: 1. ATF Suction Stage • ATF is drawn from Tank T1 via suction strainers F2 and F3. • These strainers prevent coarse particles from entering the pumps. 2. Pressurisation Stage • Pumps P1 and P2 independently pressurise the fluid. • Each has a dedicated pressure relief valve (RV1, RV2) to protect downstream components. 3. Flow Regulation Stage • Bypass return lines with flow control valves (CV1, CV2) allow precise adjustment of flow rate and pressure. • This enables tuning for different aggregate types—some require soft flushing, some require aggressive high-flow flushing. 4. Multi-Stage Filtration Fluid then passes successively through filters F4, F5, F6—creating a progressive filtration gradient that ensures sub-micron level contamination is removed before entering the UUT. 5. Distribution Header • The clean ATF is routed through a controlled header feeding multiple ball valves (BV8, BV9, BV10, BV11). • Operators can choose single- or multi-line flushing depending on aggregate complexity. 6. Pressure Feedback Loop • Gauges PG1 and PG2 allow operators to monitor pressure stability throughout the flushing cycle. Drain & Recovery Loop: After circulating through the aggregate: • ATF drains into Sink B1, which captures the fluid efficiently. • It flows into Tank T2, allowing separation of trapped contaminants. • Pump P3 then transfers this fluid back into Tank T1 via fine filters F7 & F8 to ensure only cleaned fluid re-enters the loop. This closed-loop filtration ensures extremely low operational fluid wastage and long-term cost efficiency. 3.2 Pneumatic Circuit The pneumatic section supports aggregates requiring air actuation or pressure-assisted internal movement. Components & Functionality: • Filter F9: Removes moisture and particulates from the incoming air. • Pressure Regulator PRV1: Allows precise setting of required actuation pressure. • Ball Valves BV18 & BV19: Provide controlled isolation of the air supply. • Pressure Gauge: Displays current working pressure for operator assurance. Operational Roles: • Actuation of air-operated valves inside aggregates • Supporting internal spools during flushing • Aiding flow direction changes or dynamic simulation 3.3 Drive & Loading Unit Certain aggregates—especially fuel pumps, hydraulic pumps, scavenge pumps, or gear-type equipment—contain rotational components. Proper flushing requires rotation to simulate internal fluid churning and boundary-layer removal. Key Features: • Drive Motor (M4) with adjustable speed knob • Mechanical fixtures for securely mounting aggregates • Integrated sink for capturing and isolating used ATF • Safety guards and torque-managing fixtures Advantages of Dynamic Rotation: • Prevents stagnation zones inside the aggregate • Enhances detachment of internal debris • Mimics operational behaviour, improving flushing accuracy • Helps identify abnormal noises, vibrations, or flow restrictions 3.4 Working Medium: Aviation Turbine Fluid (ATF) ATF is specifically chosen for its compatibility with aviation-grade components. Fluid Properties: • Density: 775–840 kg/m3 at 15°C • Viscosity stability: Suitable for both low- and high-temperature clean-out • Temperature Range: 15–40°C • Flash Point: 38°C • Tank Capacity: 300 litres Why ATF? • Excellent lubricity • Does not react with aggregate seals, metals, or coatings • Ensures minimal shear thinning during high-flow cycles • Maintains consistent performance across a wide temperature window 3.5 Electrical Control Panel (Highly Detailed) The control panel provides a centralised interface for operating all functions of the rig. Main Elements: • Switches & Indicators for pumps M1, M2, M3 • Drive Motor M4 panel with speed adjustment knob • Temperature controller and digital temperature indicator • Over-temperature protection indicator • Fluid level indicators (High/Low) for both T1 & T2 • 27 VDC (10A) power source for auxiliary electronics • Emergency stop & safety relays (inferred from standard design practices) Operator Capabilities: • Start/stop all pump stages • Adjust drive speed for dynamic flushing • Monitor fluid temperature and pressure • Detect tank low/high levels • Identify fault conditions in real-time The panel is laid out for fast troubleshooting, intuitive operation, and safety compliance. 4. Quality Assurance & Testing The equipment is built under a structured Quality Assurance Plan (QAP) with strict aviation requirements. Key Quality Activities: • 100% visual inspection for welds, tubing, assembly alignment • Material certification: For tanks, pipes, fittings • Dimensional checks: Ensure exact fitment of all assemblies • Pressure testing: For hydraulic lines, tanks, fittings • Electrical compliance testing: For motors, sensors, transmitters • Painting thickness measurement: Minimum 100 microns • Functional testing: Verification of pumps, motor performance, flow stability • FAT (Factory Acceptance Test): Validation after assembly • SAT (Site Acceptance Test): Final verification at installation site Documentation Delivered: • Inspection reports • Material certificates • FAT & SAT protocols • Compliance matrices • Operating manuals This guarantees the system meets aerospace-grade reliability and repeatability. 5. Technical Specifications Table
