• Track Condition Monitoring — detection of stiffness variation, settlement, gauge widening, or alignment faults. • Vehicle Dynamics Research — validation of suspension and bogie models. • Ride Comfort & Safety Assessment — correlation of vertical/lateral force spectra with ride quality indices. • Derailment Prediction & Model Verification — empirical data for NUCARS / SIMPACK and in-house RDSO models. • Maintenance Planning — predictive intervention based on force-map analytics. • Educational & Research Platform — postgraduate instrumentation and dynamics experiments at IIT Kanpur and RDSO.
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Overview and Purpose Every high-pressure system—whether on an aircraft, a missile platform, or a heavy industrial press—depends on components that must not fail under extreme hydraulic stress. A single weak link, such as a leaking connector or an under-strength valve, can compromise an entire assembly. The Neometrix Hydraulic Proof Pressure Test Rig is engineered to eliminate such risks by verifying that each component can safely endure pressures far exceeding its rated operating level. This test rig is designed to conduct hydrostatic proof tests on hydraulic components. It subjects the item under test to controlled overpressure—typically 1.5 to 2.0 times its maximum operating pressure—and holds that pressure for a defined dwell time. The test confirms that the component does not leak, deform, or lose integrity under proof conditions. Unlike burst testing, which deliberately drives a component to failure, the proof test is non-destructive. The tested item remains intact and qualified for further use. In simpler terms, if a component is expected to contain pressure, this rig ensures it truly can. Function and Testing Principle The rig performs hydrostatic proof testing in accordance with international and defence-grade standards. It applies a controlled hydraulic pressure using mineral oil or compatible test fluid and monitors the pressure decay or deformation response over time. The pressure ramp, dwell duration, and depressurization rate are fully programmable through a PLC-based control system. The machine ensures compliance with the following standard methodologies: • ISO 19879 — Hydraulic fittings and connectors • ISO 1402 — Rubber and thermoplastic hoses • SAE J343 / J517 — Hydraulic hose assemblies • EN 12266-1 — Valve pressure tests • ASTM E1003 — Hydrostatic leak test method • MIL-STD-810 — Environmental and structural qualification for defence hardware Each test cycle is logged automatically with time-stamped data, forming part of the component’s quality record. Mechanical and Hydraulic Architecture Frame and Enclosure • Fabricated steel frame with powder-coated finish for corrosion resistance. • Stainless steel (SS304) test chamber with drain outlet and splash-proof lid. • Integrated viewing window for safe operator observation. • Door interlocks and safety switches prevent pressurization when open. • Compact footprint with vibration-damped caster base for ease of movement. Hydraulic Power Unit • Multi-pump configuration driven by three electric motors (visible in the base section): o High-pressure pump for main proof testing. o Low-pressure charging pump for prefill and flushing. o Return pump for circulation and cooling. • Filtration Assembly: Duplex filter setup (10 μm and 3 μm) on pressure and return lines. • Reservoir System: Dual oil tanks (operational and clean return) with level gauges, breathers, and sampling ports. • Valving and Piping: Stainless-steel manifolds, seamless tubing, and high-pressure fittings rated above 700 bar. • Pressure Regulation: Precision pressure control valves and mechanical relief valves for overpressure protection. Control and Instrumentation • Industrial PC (Advantech S10) integrated with an AOC industrial monitor for human–machine interface. • PLC-based automation for sequence control and interlocking. • Real-time display of pressure, temperature, and flow parameters. • Pressure transducers with ±0.25% FS accuracy, calibrated to traceable standards. • High-precision analog gauge for redundant safety verification. • Programmable test sequences: fill → ramp → hold → depressurize. • Data logging software for generating automatic test certificates. Performance Specifications
