Aircraft Electro-Hydraulic Multi-Channel Power Drive Loading Rig

Aircraft Actuator Test Benches: Advanced Solutions for Aerospace Validation Modern aerospace maintenance and development demand highly accurate and repeatable actuator testing capabilities. An aircraft actuator test bench provides a controlled environment to evaluate the performance, endurance, and reliability of electro-hydraulic and electromechanical actuation systems used across flight-control architectures. These systems integrate precision hydraulics, intelligent power drive modules, and advanced load-simulation technologies to deliver comprehensive testing for both OEM and MRO requirements. An electro-hydraulic actuator testing system or aircraft power drive loading rig enables simulation of real flight loads, ensuring actuators respond correctly under dynamic conditions. With high-pressure hydraulic supplies, multi-channel digital controllers, and fault-insertion capabilities, a flight control actuator test equipment setup ensures accurate verification of extension force, retraction speed, leakage, hysteresis, and control loop behavior. For MRO workflows, an MRO actuator testing rig streamlines inspection, functional testing, and post-overhaul certification. Meanwhile, an aerospace actuator validation system and aerospace qualification test equipment support OEM-level development, durability trials, and environmental compliance. A multi-channel power drive test bench allows synchronized testing of multiple actuators, while an actuator dynamic load simulation system recreates aerodynamic forces to evaluate actuator stability and structural compatibility. The integration of a hydraulic loading rig for aircraft supports high-pressure endurance cycles, ensuring reliable long-term actuator performance. From control surface actuators to landing gear mechanisms, an aircraft control surface actuator tester delivers precise results for safety-critical components. Modern aviation test benches for actuators offer complete digital control, automated reporting, and scalability for both development and maintenance applications, making them indispensable tools for today’s aerospace industry.

About

In aviation, the difference between a flawless actuator response and a millisecond hesitation can define the line between mission success and catastrophic failure. Flight-control actuators are responsible for moving the aircraft’s most vital surfaces—ailerons, elevators, rudders, flaps—and they must perform with absolute reliability under extreme aerodynamic loads, turbulence, rapid directional reversals and fatigue stress across thousands of flight cycles. A single undetected defect can compromise controllability, risking lives and entire aircraft platforms. The Aircraft Electro-Hydraulic Multi-Channel Power Drive Loading Rig is engineered to eliminate that risk. This advanced, computer-controlled simulation platform recreates real- world flight loads—up to 24,000 kgf—and measures actuator displacement, response speed, dynamic behaviour, leakage integrity, redundancy balance and stall characteristics with uncompromising precision. By replicating real aerodynamic forces on the ground, the system guarantees that every actuator installed on an aircraft is proven airworthy, fault- free and mission-ready before it ever leaves the hangar. With a high-pressure hydraulic power system, lever-amplified load mechanics, intelligent multi-channel data acquisition and fully automated reporting, the rig delivers a repeatable, traceable, engineering-grade validation ecosystem. It is a critical asset for aerospace OEM qualification, military depots, civil aviation MRO centres, R&D laboratories and accident/failure forensic analysis, ensuring that flight safety is never left to chance—but verified beyond doubt.

Parameter	Specification
Max Force Output	~24,000 kgf
Displacement Range	up to 250 mm travel
Speed of Movement	up to ~380 mm/s
Working Pressure	10/50–250 kgf/cm² (280 kgf/cm² max)
Pump Flow Rate	≥ 45 LPM @ ~250 kgf/cm²
Hydraulic Tank	~60 L stainless steel
Hydraulic Oil	AMG-10 / AMG-10B or equivalent
Oil Cleanliness	NAS Class 4
Load Cell	30,000 kgf
Power Supply	415 V AC, 3-Phase, 50 Hz
DC Output to UUT	0–30 V DC, 5 A
Cooling Water	30–60 LPM, 6 bar @ 20°C
Cylinder Strokes	±125 mm and ~105 mm
Operating Temperature	25–40°C maintained

• Qualification testing of new aircraft flight-control actuators • Periodic proof testing and health assessment for MRO & fleet life extension • Engineering analysis of actuator dynamics, response curves, damping & hysteresis • R&D simulation for actuation system behaviour under varied load conditions • Troubleshooting of defective or unstable control drives

Details

Introduction
The Aircraft Electro-Hydraulic Multi-Channel Power Drive Loading Rig is a sophisticated, computer-controlled testing platform engineered to simulate real flight-control operating conditions for aircraft electro-hydraulic actuators and multi-channel power drive units. These systems form the backbone of modern aircraft control surfaces (ailerons, elevators, rudders, spoilers and high-lift systems) and must deliver high force, precise displacement and reliable dynamic response under varying loads and hydraulic conditions.

To ensure aircraft safety and mission readiness, actuators require rigorous acceptance testing, qualification testing, periodic inspection, life-cycle endurance testing and troubleshooting under controlled laboratory conditions. This Loading Rig recreates in-service aerodynamic loads and dynamic movements, enabling engineers and maintenance teams to accurately validate actuator behaviour, torque capability, load balance between channels, hydraulic leakage, temperature influence, dynamic response curves, stall behaviour and safety-critical performance thresholds.

The system integrates a high-pressure electro-hydraulic power pack, dual independent loading cylinders with precision lever-based mechanical load transfer, high-accuracy instrumentation, multi-channel DAQ system and PC-based control automation in a compact, rugged steel frame suitable for both R&D centres and MRO facilities. It is built to operate continuously under high load conditions while maintaining hydraulic cleanliness, thermal stability and measurement repeatability.

Functional Capability & Purpose
The test bench is designed to simulate static, quasi-static and dynamic loads on aircraft power drives, enabling the following operations:
• Measurement of output load/force up to approx. 24,000 kgf applied at the actuator output shaft or linkage via mechanical lever.
• Displacement / stroke measurement over the full travel of the actuator.
• Speed measurement of the output link during extension / retraction cycles up to approx. 380 mm/s.
• Dynamic response evaluation including rate control, overshoot, hysteresis, and system stiffness.
• Leakage and air-tightness verification under static or dynamic load conditions.
• Thermal behaviour monitoring under extended operation cycles.
• Functional performance comparison between redundant channels in multi-path actuators.
• Safety cut-off and stall response validation under extreme loading.
Software provides data logging, live graphs, automated report generation and secure database archiving.

System Architecture
The test system consists of three fully integrated subsystems engineered to function as a unified platform:
1. Hydraulic Power Pack / Pumping Station
A high-pressure electro-hydraulic power unit designed for stable flow and pressure delivery during complex test sequences.
• Electric motor 25 HP, 3-Phase 415 V AC powering
• Variable-displacement axial piston pump (approx. 45 LPM at 245–250 kgf/cm2)
• Stainless steel hydraulic reservoir, approx. 60 L capacity
• Multi-stage high-pressure filtration chain (20 μm + 8 μm + 5–6 μm)
• NAS Class 4 hydraulic cleanliness using clogging indicators
• Plate-type water-cooled heat exchanger maintaining 25–40 °C oil temperature
• Safety sensors and protections: low-level shutdown, high-temperature alarm, motor overload, phase failure, filter clog, emergency stop
• Internal hydraulic manifold with servo-grade solenoid valves, pressure-relief valves and shut-off valves

The closed-loop pressure control permits accurate load replication without pressure drop fluctuations during dynamic transitions.

2. Loading Frame & Mechanical Power Transfer System
A heavy-duty fabricated steel structure engineered for vibration-free operation and high load endurance.
• Rigid load frame with hardened mounting interface for various actuator sizes
• Dual hydraulic loading cylinders:
  ▹ Constant-load cylinder (effective area ~68 cm2, stroke ±125 mm)
  ▹ Positional/dynamic-load cylinder (effective area ~160 cm2, stroke ~105 mm)
• Precision leverage mechanism enabling moment amplification to match aircraft load geometry
• Universal high-precision load cell (approx. 30,000 kgf) in the direct load path for force measurement
• High-accuracy LVDT (up to 250 mm travel) for displacement/speed measurement
• Guided track and bearing blocks to control alignment and reduce side-loads
• Integrated stainless steel drip tray to collect oil leakage and route back to tank The mechanical amplification design reproduces real aerodynamic loads efficiently while minimising hydraulic stroke requirements.

3. Control & Instrumentation System
An industrial automation architecture combining PLC/DAQ hardware and powerful PC software interface.
• Industrial PC with custom software for real-time testing and data visualisation
• 64-channel high-resolution DAQ, 32-bit sampling
• Multi-channel instrumentation: load, displacement, speed, temperature, differential pressure, power supply monitoring
• User-friendly GUI for:
  ▹ Test profile creation and sequence management
  ▹ Monitoring live plots (Force–Time, Displacement–Time, Speed–Displacement)
  ▹ Report export in PDF & Excel formats with job tracking metadata

• Operator Panel including:
  ▹ Start/Stop controls, valve actuation switches
  ▹ Pressure and temperature digital indicators
  ▹ Emergency Stop system

Key Features & Advantages
• Purpose-built for aircraft flight-control electro-hydraulic power drives
• Realistic aerodynamic load simulation with lever-based force amplification
• Fully computerised test execution, logging and automatic reporting
• High measurement precision with ±0.25% instrumentation accuracy
• Dual-path loading suitable for multi-channel actuator redundancy validation
• Triple-stage filtration achieving NAS 1638 Class 4 cleanliness
• High safety & fail-safe protection levels with alarms & shutdown logic
• Modular construction allowing easy upgrades and service accessibility
• Suitable for OEM qualification, MRO inspection, R&D, and training

Technical Specifications (Indicative / Customisable)

  
    Parameter
    Specification
  

  
    Max Force Output
    ~24,000 kgf
  

  
    Displacement Range
    up to 250 mm travel
  

  
    Speed of Movement
    up to ~380 mm/s
  

  
    Working Pressure
    10/50–250 kgf/cm² (280 kgf/cm² max)
  

  
    Pump Flow Rate
    ≥ 45 LPM @ ~250 kgf/cm²
  

  
    Hydraulic Tank
    ~60 L stainless steel
  

  
    Hydraulic Oil
    AMG-10 / AMG-10B or equivalent
  

  
    Oil Cleanliness
    NAS Class 4
  

  
    Load Cell
    30,000 kgf
  

  
    Power Supply
    415 V AC, 3-Phase, 50 Hz
  

  
    DC Output to UUT
    0–30 V DC, 5 A
  

  
    Cooling Water
    30–60 LPM, 6 bar @ 20°C
  

  
    Cylinder Strokes
    ±125 mm and ~105 mm
  

  
    Operating Temperature
    25–40°C maintained
  


Applications
• Qualification testing of new aircraft flight-control actuators
• Periodic proof testing and health assessment for MRO & fleet life extension
• Engineering analysis of actuator dynamics, response curves, damping & hysteresis
• R&D simulation for actuation system behaviour under varied load conditions
• Troubleshooting of defective or unstable control drives

Summary
The Aircraft Electro-Hydraulic Multi-Channel Power Drive Loading Rig is a mission-critical test platform for validating the performance and safety compliance of aircraft control actuators under realistic loads. Its combination of precision hydraulics, advanced data acquisition, load simulation accuracy and automated reporting makes it essential equipment for aerospace OEMs, research laboratories, military depots and civil aviation MRO workshops.