• Testing and validation of Hydro-Gas Suspension Units used in main battle tanks and infantry fighting vehicles (T-72, T-90, BMP-II, Arjun MBT, K9 Vajra, etc.). • Qualification and acceptance testing of HSU components after manufacturing, overhaul or repair. • Verification of seal integrity, proof pressure capability and structural strength of suspension struts. • Dynamic damping evaluation through jounce–rebound simulation to certify energy absorption behaviour. • Generating force-velocity, pressure-flow and hysteresis profiles for compliance with OEM standards. • Conditioning and flushing of HSUs during maintenance, including oil replacement and purge cycles. • Calibration and benchmarking of hydraulic–gas suspension units for R&D, performance tuning and failure analysis. • Laboratory simulation of battlefield shock loads and terrain-induced forces for mobility system assessment.
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1. Introduction: Mastering the "Iron Legs" of Armored Warfare In the unforgiving theatre of modern warfare, a Main Battle Tank’s (MBT) survivability is defined by three pillars: Firepower, Protection, and Mobility. While armor deflects shells and cannons engage targets, it is the suspension system that allows a 45-to-60-ton behemoth to traverse cross-country terrain at tactical speeds while keeping its main gun stabilized. The Neometrix Hydro-Gas Suspension Test Rig is the definitive ground-support solution designed to ensure that this critical mobility never fails. Engineered specifically for the complex Hydro-Pneumatic Suspension Units (HSU) found on platforms like the T-72, T-90, BMP-II, K9 Vajra, and Arjun MBT, this system bridges the gap between brute force and surgical precision. Unlike conventional mechanical springs, HSUs utilize compressed Nitrogen gas as a spring and hydraulic fluid as a damper—a sophisticated interplay that requires exact calibration. This test rig serves as a "virtual proving ground." It is capable of simulating the violent jounce (compression) and rebound (extension) forces a tank experiences in the field, all within a controlled laboratory environment. By delivering high-pressure hydraulic actuation up to 400 Bar and monitoring response curves with digital accuracy, the Neometrix Test Rig guarantees that every suspension strut leaving the workshop is ready to absorb the shock of the battlefield, protecting both the vehicle’s sensitive electronics and its crew from debilitating fatigue. 2. System Architecture & Engineering Specifications The test facility is designed as a modular, skid-mounted system comprising two primary subsystems: the Hydraulic Power Generation Unit (HPU) and the Command & Control Station. A. Hydraulic Power Unit (HPU) – The Kinetic Source The HPU is a continuous-duty hydraulic station designed to deliver non-pulsating flow at high pressures. • Reservoir Construction: Fabricated from SS-304 or heavy-gauge mild steel with an approximate capacity of 400–600 Liters (configurable up to 1000L for larger benches). It features: ▹ Internal baffling to enforce laminar flow and promote de-aeration. ▹ Magnetic suction separators to trap ferrous contaminants. ▹ Desiccant breathers to prevent atmospheric moisture ingress. • Prime Mover: 3-Phase AC Induction Motor (Industrial Grade, IE3 Efficiency), typically rated between 30kW and 45kW depending on flow requirements, operating at 1440 RPM. • Pumping Group: ▹ Primary Pump: Variable Displacement Axial Piston Pump (e.g., Parker PV Plus series or equivalent) equipped with Load Sensing (LS) and Pressure Compensator (P-Comp) controls to minimize heat generation during idle states. ▹ Secondary Circuit: External gear pumps utilized for cooling loops and pilot pressure generation. • Filtration Architecture (NAS 1638 Class 6 Compliance): ▹ Pressure Line: 3-micron absolute high-collapse filters to protect the Unit Under Test (UUT). ▹ Return Line: 10-micron filters to capture contaminants flushed from the UUT. ▹ Clog Indicators: Electronic differential pressure switches linked to the PLC to trigger "Filter Clog" alarms before bypass occurs. • Thermal Management: An active Shell & Tube or Air-Blast Heat Exchanger (Chiller) sized to dissipate up to 30% of input power, ensuring hydraulic oil temperature remains between 40°C and 55°C during endurance cycling. B. Instrumentation & Control – The Digital Core The system utilizes a PC-based automation architecture housed in an IP54-rated Rittal-style industrial cabinet. • Software Environment: Custom-developed National Instruments LabVIEWTM application running on an Industrial PC (IPC). • Data Acquisition (DAQ): High-speed sampling (up to 1 kS/s) for capturing transient pressure spikes during rapid valve actuation. • Telemetry & Sensors: ▹ Pressure Transducers: Strain-gauge based sensors with 0.25% F.S. accuracy (Range: 0–400 Bar). ▹ Flow Meter: High-response Turbine or Gear-type flow meter (Range: 0–300 LPM) installed in the return line to characterize damping fluid displacement. ▹ Linear Position Sensors (LVDT): (Optional) Integrated into the actuator to correlate pressure vs. displacement (Force-Displacement loops). 3. Comprehensive Operational Capabilities The Neometrix HSU Test Rig is engineered to validate the full performance spectrum of hydro-pneumatic units. Mode 1: Static Proof & Seal Integrity Test • Function: Verifies the structural strength of the cylinder body and the holding capability of the rod seals. • Protocol: The system pressurizes the HSU to 1.5x Operating Pressure (typically up to 350 Bar or 1000 Bar for specific proof tests). The supply is isolated via leak-free poppet valves. • Acceptance Criteria: The software monitors pressure decay over a fixed duration (e.g., 180 seconds). Any drop exceeding the specified tolerance (e.g., >2 Bar) triggers a "FAIL" status, indicating internal bypass or external leakage. Mode 2: Dynamic Damping Characterization (Jounce/Rebound) • Function: Validates the HSU’s ability to dissipate kinetic energy. • Protocol: ▹ Jounce (Compression Simulation): High-flow solenoid valves direct fluid to the piston side, simulating the rapid upward movement of the road wheel during terrain impact. The system measures the pressure rise required to achieve a specific flow rate. ▹ Rebound (Extension Simulation): The valves reverse, forcing fluid out of the unit to simulate the wheel returning to position. The system measures the flow restriction (damping force) provided by the HSU's internal orifices. • Output: The system generates a Hysteresis Loop (Force vs. Velocity) or Pressure vs. Flow graph. These curves are overlaid against the OEM \"Gold Standard\" envelope to certify the component. Mode 3: Fluid Conditioning & Charge/Purge • Function: Automated maintenance cycle. • Protocol: The rig circulates clean oil through the HSU to flush out degraded fluid and particulate matter (metal shavings, seal debris). It then recharges the unit with fresh MIL-H-5606 or OM-15 hydraulic fluid to the precise volumetric level required for the nitrogen gas spring to function correctly. 4. Technical Data Sheet
