This versatile test rig serves a broad array of industries: • Aerospace & Defense: Qualify flight-control actuators through repeated cyclic loading that replicates maneuvers, ensuring reliability in extreme conditions. • Heavy Machinery: Validate hydraulic cylinders and rotary actuators used in cranes, excavators, and presses for long-term durability under changing inertial forces. • Automotive: Test braking and steering hydraulic assemblies under rapid acceleration/deceleration cycles to verify response time and structural integrity. • Energy & Power Generation: Fatigue-test hydraulic power units in turbines and offshore platforms, simulating load reversals common in start-stop and load-shedding scenarios.
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1. Introduction & Purpose The Inertial Loading Test Facility is a fully integrated system designed to subject hydraulic actuators, manifolds, and power packs to precisely controlled inertial loads that emulate real-world dynamic conditions. Rather than relying solely on static pressures, this facility uses interchangeable mass blocks and high-response hydraulic control to reproduce acceleration, velocity, and force profiles representative of actual service environments. This capability ensures that your components are validated not just for pressure endurance but for fatigue life and control fidelity under true dynamic loading. 2. Applications This versatile test rig serves a broad array of industries: • Aerospace & Defense: Qualify flight-control actuators through repeated cyclic loading that replicates maneuvers, ensuring reliability in extreme conditions. • Heavy Machinery: Validate hydraulic cylinders and rotary actuators used in cranes, excavators, and presses for long-term durability under changing inertial forces. • Automotive: Test braking and steering hydraulic assemblies under rapid acceleration/deceleration cycles to verify response time and structural integrity. • Energy & Power Generation: Fatigue-test hydraulic power units in turbines and offshore platforms, simulating load reversals common in start-stop and load-shedding scenarios. 3. Core Components & Features 3.1 Reaction Brackets The heart of the structure comprises dual reaction brackets—one horizontal, one vertical—fabricated from IS-2062 mild steel and bolted to your facility’s strong floor and shear wall. Each bracket is reinforced with closely spaced ribs to withstand dynamic loads of ±160 kN at the actuator’s center line, minimizing frame deflection and eliminating spurious resonances during high-speed testing . 3.2 Antifriction Guide & Modular Mass Blocks A precision antifriction guide allows the mass carriage to travel ±150 mm horizontally and ±100 mm vertically. Hardened guide rails and recirculating bearings ensure positional accuracy down to 2 μm over every 1 000 mm of travel, even at accelerations up to 2 g and velocities approaching 2 m/s. The inertial load is applied via modular mass blocks in 500 kg increments, up to a total of 2 000 kg, with the center-of-gravity maintained precisely on the actuator axis for repeatable, balanced loading . 3.3 Hydraulic Actuation System Two three-stage servo valves, each capable of 60 L/min at 210 bar, work in concert with four strain-gauge pressure transmitters (ranges 0–400 bar and 0–700 bar, ±0.1 % full-scale accuracy) to create a closed-loop control environment. All hydraulic piping is butt-welded and radiographed in accordance with ASME Section IX, and hoses meet SAE 100R11 and 100R8 standards. This robust hydraulic interface delivers rapid, precise control of position, velocity, and acceleration, even under full inertial load . 3.4 Control & Data Acquisition An industrial-grade PLC runs at a 1 kHz control loop frequency over EtherCAT, ensuring millisecond-level response. A 12′′ capacitive touchscreen HMI provides intuitive test setup, live trend graphs, and alarm handling. Data acquisition is handled by a 16-channel, 24-bit DAQ system sampling up to 5 kS/s per channel, capturing encoder position (1 μm resolution), pressure signals (4–20 mA or ±10 V), and optional accelerometer inputs for advanced analysis. 4. Technical Specifications
