Details
The Hydraulic Test Rig for Rear Cover Sub-Assembly (Model A1110) by Neometrix Group is an advanced testing solution specifically engineered to evaluate the structural integrity, hydraulic performance, and reliability of tractor rear cover assemblies. It features automated and manual testing modes, precision hydraulic control with adjustable pressure and flow rates, and state-of-the-art instrumentation for accurate measurement of displacement, temperature, and pressure. Designed for demanding industrial applications, this rig offers unparalleled efficiency, repeatability, and safety, making it ideal for use in automotive manufacturing, heavy machinery, aerospace, defense, and quality assurance research environments. Comprehensive System Description 1. Main Hydraulic Power Pack • Reservoir Capacity: 500 liters, equipped to store and circulate Grade ELF 2731 brake oil. • Filtration: - Return line: Precision 10-micron filter to maintain hydraulic cleanliness. - Suction line: Robust 50-micron strainer to prevent particle ingress. • Heating System: Twin high-capacity (4 kW each) heaters ensure optimal oil temperaturefor efficient system performance. • Pump and Motor System: High-performance 15 kW/20 HP ABB electric motor paired with an ABB Variable Frequency Drive (VFD), allowing precise control over motor speeds and system pressures. • Contamination Control: Integrated magnetic tank cleaner for capturing metallic impurities and ensuring extended component life. 2. Loading Hydraulic Power Pack • Reservoir Capacity: 300 liters designed to handle VG 46 hydraulic oil. • Filtration: Return line: 10-micron precision filter, suction strainer with 149 microns. • Motor and Pump Assembly: Robust ABB 2 HP motor coupled with a high-performance Rexroth gear pump capable of maintaining pressures up to 150 bar. 3. Advanced Instrumentation and Sensors • Linear Variable Differential Transformer (LVDT): Provides highly accurate, real-time measurements of linear displacement ensuring precise control of actuator movements. • Resistance Temperature Detector (RTD): Offers reliable and precise oil temperature monitoring ranging from 0-150°C, essential for maintaining optimal operating conditions. • Pressure Measurement System: Calibrated pressure transmitters and gauges from Wika, providing precise measurement up to 300 bar, ensuring consistent test conditions. • Digital Flow Meters: Pulse-output meters (Omega) accurately track fluid flow rates, enabling instantaneous, repeatable testing. 4. Hydraulic Actuation and Control Systems • Actuators: High-quality double-acting hydraulic actuators tailored for precise and repeatable testing. • Hydraulic Swing Clamps: - Heavy-duty clamps with overload protection, rated for 22.6 KN and 13.9 KN at 200 bar, ensuring secure fixture during testing. • Directional Control Valves: High-precision Rexroth 4/3 DC solenoid valves for precise fluid direction management. • Pressure Control: Equipped with relief and unloading valves to maintain accurate pressure regulation, ensuring safe operational conditions. 5. Control Interface • Touchscreen HMI: An intuitive touchscreen interface that simplifies complex operational procedures, enhances operator experience, and facilitates data visualization and logging. • Operating Modes: Flexible operation through selectable automatic and manual modes, enabling customized testing protocols tailored to specific requirements. Testing Procedure Automated Mode (AUTO Mode) • System initiates automatic sequences, beginning with oil heating (maintained between 40-60°C), secure unit clamping at 200 bar pressure, controlled motor operation, and systematic load adjustments. • Ensures precise and repeatable testing conditions and rapid execution cycles. Manual Mode • Direct user control from the rear panel, allowing independent operation of test omponents. • Ideal for specialized or diagnostic testing scenarios that demand direct intervention. Performance and Technical Specifications • Operational Pressure Range: Adjustable up to 210 bar. • Flow Rate Control: Precise adjustments available between 5 to 24 LPM, based on predefined test profiles. • Lift Arm Response Time: Consistent actuator movement response within 2.3-2.6 seconds. • Maximum Crack Pressure Testing: Capable of precise testing at pressures up to 165 bar, ensuring rigorous quality assurance. Safety Features • Comprehensive safety protocols including emergency stop buttons, protective interlocks, overload protection systems, and clearly marked operation guidelines. • Robust engineering construction compliant with stringent industrial safety standards to ensure operator safety and asset protection. Maintenance and Service Schedule • Daily: Routine cleaning and visual inspection. • Weekly: Inspection and cleaning of filtration components, magnetic cleaner rods, and sensors. • Monthly: Complete hydraulic tank and suction strainer maintenance to ensure optimal performance and longevity. Applications • Automotive Manufacturing: Comprehensive testing of rear cover sub-assemblies for tractors, trucks, and commercial vehicles. • Aerospace & Defence: Validating hydraulic components in aircraft and military equipment under stringent conditions. • Heavy Industrial Equipment: Testing hydraulic sub-assemblies used in heavy machinery, ensuring operational integrity and reliability. • Research & Development: Used in laboratory settings for precision testing, analysis, and validation of new component designs. Why Choose Neometrix's Hydraulic Test Rig? • Precision and Accuracy: Integrated with top-tier sensor and instrumentation technology to deliver highly accurate test outcomes. • Operational Versatility: Provides flexibility with automated and manual testing options suitable for diverse applications. • Durability and Quality Assurance: Built with premium-grade materials and components, ensuring long-term reliability and consistent performance. • Exceptional Technical Support: Backed by Neometrix’s experienced team of engineers, offering expert guidance, comprehensive after-sales service, and technical assistance.
