• Performance testing of multi-channel aircraft actuators • Verification of linear force output, displacement, and stroke behavior • Speed control testing of the actuator’s output link • Leak testing and SPM operational verification • Defense, aerospace, and R&D applications where electro-hydraulic actuators are employed
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Introduction The Manual Loading Rig is a specialized electro-hydraulic test system developed for the performance evaluation and validation of multi-channel power drives used in aircraft systems. This test bench simulates real-world mechanical load conditions, enabling comprehensive force, displacement, and leak tests. It combines rugged mechanical construction with sophisticated instrumentation and software-driven automation to ensure precise and repeatable test results. Key Features • Multi-Channel Electro-Hydraulic Testing Capability: Designed to test complex multi-channel actuators by measuring force, displacement, speed, and sealing performance. • Advanced Measurement System: Integrates load cells, LVDT-based displacement sensors, and digital pressure and temperature transducers. • Industrial Grade Control System: PLC- and PC-based control with NI data acquisition cards, graphical UI, and a custom-developed software suite. • Comprehensive Filtration System: Triple-stage inline filters (20μ, 10μ, 5μ) with electrical clog indicators and shutdown interlocks ensure hydraulic cleanliness up to NAS Class 4. • Efficient Thermal Management: A water-cooled heat exchanger maintains fluid temperature within the operational range of 25–40°C. • Built-In Safety Interlocks: Automatic shutdowns for motor overloads, low oil level, clogged filters, and power phase disorders. Applications • Performance testing of multi-channel aircraft actuators • Verification of linear force output, displacement, and stroke behavior • Speed control testing of the actuator’s output link • Leak testing and SPM operational verification • Defense, aerospace, and R&D applications where electro-hydraulic actuators are employed System Components & Functionality Hydraulic System: - Hydraulic Oil: AMG-10 or equivalent - Tank Capacity: 60 liters (SS-304) - Pump: 25 HP axial piston pump, 45 LPM @ 250 kgf/cm2 - Filters: Pall inline filters with 8μ, 5μ, and 20μ elements and clogging sensors - Heat Exchanger: Alfa Laval, 20 LPM chilled water at 20°C - Hoses: SS braided Teflon with 220 Bar rating Control Panel: - Dual-panel layout: Hydraulic and Electrical - 2 Digital Readouts (DROs) for temperature and flow - Digital timer, particle counters (NAS class), and emergency stop - Motor and valve ON/OFF push buttons with LED indicators Measurement & Instrumentation: - Force Measurement: Honeywell load cell, up to 30,000 kgf - Displacement & Speed: Ceresco LVDT sensors (250 mm range, 0.01% accuracy) - System Monitoring: Pressure gauges, flow meter, temperature sensor, and particle counter Software Features - Custom GUI with login-based access for operators and administrators - Calibration window for sensor adjustment - Test selection and parameter monitoring interface - Real-time fault indicators - Data logging and report generation in HTML format Technical Specifications
