• Systems integration testing for defence and aerospace hardware • Verification of release and deployment mechanisms • Operator and crew training under realistic simulated conditions • Data logging, telemetry validation, and post-mission analysis • Controlled environmental testing of mechanical assemblies and actuators
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Overview The Integration Simulator is a fully engineered, high-fidelity test and training environment designed for the integration, evaluation, and verification of complex defence and aerospace systems. Developed to meet stringent military and R&D requirements, it provides a controlled space for mechanical, electrical, and software systems to be tested together under realistic yet safe conditions. With a robust modular architecture, precise mechanical assemblies, and advanced control and data-logging capabilities, this simulator enables mission rehearsal, operator training, and performance validation across a wide range of applications. Applications • Systems integration testing for defence and aerospace hardware • Verification of release and deployment mechanisms • Operator and crew training under realistic simulated conditions • Data logging, telemetry validation, and post-mission analysis • Controlled environmental testing of mechanical assemblies and actuators Key Features Customised Structural Design • Built from high-strength aerospace alloys and high-grade structural steel for durability and load-bearing performance. • CNC-machined components with corrosion-resistant surface treatments for long-term service. • Modular frame and panel construction allowing reconfiguration and upgrades. • Fire-rated access doors and marine-grade flooring for safety and durability. • Thermal- and sound-insulated wall and ceiling panels for controlled conditions. Dedicated Functional Areas • Simulation Area – Houses the primary mechanical assemblies, actuators, suspension points, and interfacing fixtures. • Control Console Area – Equipped with industrial-grade stainless steel enclosures, operator-friendly desks, and high-resolution displays for real-time control and monitoring. • Data Recording & Monitoring Area – Workstations with high-performance processors, large storage capacity, and multi-screen setups for detailed analysis. • Storage & Utilities – Shelving, secure storage, and maintenance toolkits for operational readiness. Environmental Control • High-capacity HVAC system with precise temperature and humidity control for optimal equipment performance. • HEPA-filtered air purification for dust and particulate removal. • Oscillating wall-mounted fans and an air curtain at the entry to maintain air quality and minimise contamination. • Noise-controlled, insulated structure for comfortable and safe operation. Electrical & Networking Infrastructure • Regulated DC power rails (5V, 12V, 24V, 28V) supported by industrial SMPS units for different subsystem requirements. • Modular, labelled power outlets and ISI-certified switchgear for safety and ease of use. • High-speed network cabling infrastructure for secure data transfer between subsystems and control stations. • Integrated lighting plan for uniform, shadow-free illumination across all working zones. Control & Data Systems • Operator Consoles with ergonomic design, anti-glare HD displays, and industrial computing hardware for real-time simulation management. • Data Recording Systems with solid-state primary storage and large-capacity HDD backup for long-term test data retention. • Large-Format Review Displays for group analysis, training, and after-action review. • Fully integrated CCTV surveillance with HD, IR-enabled cameras and long-term video storage capability. Mechanical Assemblies & Test Fixtures • Precision-engineered door and latch mechanisms, clamps, mounting brackets, and suspension assemblies to replicate actual deployment hardware. • Load-bearing brackets, bulkheads, and structural frames designed to handle operational forces safely. • Electromechanical actuators with sensor feedback for accurate motion control. • Modular mechanical sub-assemblies to support a variety of test articles and scenarios. Safety Systems • Fire detection and suppression equipment, including multiple classes of fire extinguishers. • Controlled-access entry systems with biometric authentication. • Fail-safe design for critical load-bearing and release mechanisms. • Insulated marine-grade flooring for electrical and operational safety. Technical Highlights
