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Introduction The Neometrix Dual Power Hydraulic Test Rig is purpose-built to serve as the definitive verification platform for hydraulic Line-Replaceable Units (LRUs) deployed in the most demanding aerospace and defense environments. In layperson’s terms, imagine a highly sophisticated “stress-test bench” that applies controlled bursts of hydraulic fluid—even beyond normal operating limits—so that engineers can identify leaks, mechanical weaknesses, or performance drifts before components ever leave the factory. By reproducing exact field conditions in the laboratory, this rig guarantees that critical systems such as landing-gear jacks, flight-control actuators and brake assemblies will operate reliably under all circumstances. System Overview The Dual Power Hydraulic Test Rig integrates two fully independent hydraulic power systems, a large-volume fluid reservoir, comprehensive thermal conditioning and advanced digital controls into a single, turnkey solution. This architecture enables continuous operation—without interruption—for long-duration proof, burst, impulse and endurance sequences. All major components are mounted on a reinforced steel skid with integrated leveling feet and forklift channels, ensuring straightforward installation and mobility within any industrial test cell environment. Power Units 1. Main Power Pack • Pump Type: Parker PV Plus axial-piston, 63 cc/rev, renowned for high volumetric efficiency and low noise levels. • Electric Drive: 60 HP (45 kW) TEFC motor, 4-pole design, delivering 1470 RPM at 415 VAC, 50 Hz. • Performance Envelope: Continuous duty up to 350 bar at 80 LPM; certified safe-operating-limit up to 450 bar. • Cooling: IP55 motor housing with external fan ensures thermal stability under continuous operation. 2. Standby Power Pack • Pump Type: High-pressure gear pump producing up to 80 LPM. • Motor: Secondary 15 kW TEFC motor; engages automatically upon detection of main-pump fault or scheduled maintenance. • Pressure Regulation: Panel-mounted pilot relief valve adjustable from 10 to 200 bar, providing immediate load relief and maintaining test continuity. • Fail-Safe Switching: Pressure sensors and PLC logic manage seamless switchover with less than 2 seconds of downtime. Hydraulic Reservoir & Thermal Conditioning • Reservoir Construction: 400 L capacity fabricated from SS-304 stainless steel with anti-cavitation baffle and internal deflector plates to minimize aeration. • Fluid Monitoring: Integrated level switch, manual sight glass and temperature probe provide real-time status. • Active Temperature Control: - Chiller: Air-cooled, 30 000 kcal/h unit maintains oil temperature between 10 °C and 48 °C to replicate arctic to desert climates. - Heater: 4 kW immersion heater controlled via PID loop for ±0.1 °C stability. • Accumulator / Dampener: 1 L piston-type unit smooths pulsations, ensuring steadier pressure delivery and more accurate test data. Filtration & Fluid Quality Maintaining hydraulic-fluid cleanliness is vital for repeatable, long-term testing. This rig employs six sequential filters:
