• Hydraulic Power Unit: Fixed-displacement gear pump (22.5 cc/rev) driven by a 3-phase, 415 VAC induction motor; flow up to 30 L/min; maximum system pressure 100 bar. • Instrumentation Accuracy: Turbine flow meters ±1% accuracy; pressure transducers ±0.5% FS; analog-to-digital sampling at 1 kHz for dynamic pressure profiling. • Control Electronics: Rockwell/Siemens PLC with 16 ms program scan; industrial-grade VFD supporting torque-limit and closed-loop current control; 24 VDC safety I/O with cross-monitoring. • Software Environment: Windows 10/11 compatible HMI, built on .NET 5 framework; SQL Server 2019 backend; OPC UA interface for SCADA integration. • Physical Footprint & Utilities: 2 m × 1.5 m footprint; 2.5 m height; 500 kg total mass; power draw 5 kW peak; pneumatic supply option 6 bar at 50 LPM.
▹ In OEM production lines, the ARJUN NOVO ensures that every PST unit leaving the factory meets stringent manufacturer tolerances. An identical test program can be deployed across multiple assembly stations, providing standardized results and eliminating operator variability. ▹ After-sales service centers leverage the rig’s diagnostic capabilities to evaluate remanufactured or repaired PSTs—pinpointing deviations in modulation curves that could lead to jerky shifts or hydraulic lock-ups in the field. This dramatically reduces return visits and warranty claims. ▹ Research and development teams use the rig for endurance testing, cycling units through tens of thousands of shifts to generate life-cycle data and identify potential fatigue points in spool valves or seals. Users can adjust pressure ramp rates and temperature set-points to stress-test new PST designs under accelerated aging protocols. ▹ Finally, in technical training sessions, the rig serves as a “live classroom,” allowing trainees to observe pressure-flow graphs in real time, learn how valve geometry affects clutch performance, and practice troubleshooting via built-in fault-injection modes.
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Introduction The Power Shuttle Transmission Test Rig (“ARJUN NOVO”) is engineered to replicate the exact hydraulic and mechanical conditions encountered by Power Shuttle Clutch (PST) units in modern agricultural tractors. Unlike conventional transmission tests that require manual shifting, this rig automates the process of forward, neutral, and reverse actuation, using an electro-hydraulic valve to mimic on-the-fly direction changes. By reproducing the full range of pressure spikes, flow rates, and temperature variations seen in the field, the system verifies clutch engagement smoothness, response speed, and leakage performance—all within a controlled laboratory environment. This not only accelerates end-of-line quality assurance but also uncovers subtle wear-related issues before they can impact tractor operation. Applications ▹ In OEM production lines, the ARJUN NOVO ensures that every PST unit leaving the factory meets stringent manufacturer tolerances. An identical test program can be deployed across multiple assembly stations, providing standardized results and eliminating operator variability. ▹ After-sales service centers leverage the rig’s diagnostic capabilities to evaluate remanufactured or repaired PSTs—pinpointing deviations in modulation curves that could lead to jerky shifts or hydraulic lock-ups in the field. This dramatically reduces return visits and warranty claims. ▹ Research and development teams use the rig for endurance testing, cycling units through tens of thousands of shifts to generate life-cycle data and identify potential fatigue points in spool valves or seals. Users can adjust pressure ramp rates and temperature set-points to stress-test new PST designs under accelerated aging protocols. ▹ Finally, in technical training sessions, the rig serves as a “live classroom,” allowing trainees to observe pressure-flow graphs in real time, learn how valve geometry affects clutch performance, and practice troubleshooting via built-in fault-injection modes. Key Features ▹ High-Precision VFD Control: 3.7 kW VFD adjusts pump speed in 0.1 Hz steps for accurate flow and pressure regulation. ▹ Triple-Channel Hydraulic Monitoring: Three flow channels with turbine meters and ±0.5% transducers for leakage and performance insights. ▹ Automated Sequencing & Fault Injection: Built-in recipes with dwell, ramp profiles, and fault modes to validate system and safety interlocks. ▹ Integrated Data Suite: Barcode-based part logging and auto-PDF reports with modulation curves, histograms, and trend analysis. ▹ Robust Safety Architecture: Dual-stop circuits, temperature alarms, and hydraulic interlocks meeting ISO 13849-1 Cat 3 standards. Technical Specifications • Hydraulic Power Unit: Fixed-displacement gear pump (22.5 cc/rev) driven by a 3-phase, 415 VAC induction motor; flow up to 30 L/min; maximum system pressure 100 bar. • Instrumentation Accuracy: Turbine flow meters ±1% accuracy; pressure transducers ±0.5% FS; analog-to-digital sampling at 1 kHz for dynamic pressure profiling. • Control Electronics: Rockwell/Siemens PLC with 16 ms program scan; industrial-grade VFD supporting torque-limit and closed-loop current control; 24 VDC safety I/O with cross-monitoring. • Software Environment: Windows 10/11 compatible HMI, built on .NET 5 framework; SQL Server 2019 backend; OPC UA interface for SCADA integration. • Physical Footprint & Utilities: 2 m × 1.5 m footprint; 2.5 m height; 500 kg total mass; power draw 5 kW peak; pneumatic supply option 6 bar at 50 LPM. Operating Principle At the heart of the rig lies a closed-loop hydraulic circuit. Upon receiving a shift command from the PLC, the VFD adjusts motor RPM to achieve the desired flow rate through the gear pump. Oil is directed through a proportional directional valve, which, under electrical control, positions the PST spool to forward, neutral, or reverse. As the spool moves, flow meters and pressure transducers capture time-stamped data, producing a modulation-curve profile that reflects spool displacement versus hydraulic pressure. The HMI software overlays these profiles on a reference “golden” curve, instantly flagging any deviations. Advanced routines also vary oil temperature via an optional heat exchanger, evaluating performance under cold-start or elevated-temperature conditions. Installation Requirements • Electrical: Dedicated three-phase 415 VAC ±10%, 50 Hz supply; 20 A circuit breaker with earth-leakage protection. • Pneumatic (Optional): 6 bar dry, filtered air at 50 LPM for pneumatic valve actuation and safety interlocks. • Spatial Needs: 2 m (L) × 1.5 m (W) footprint; 2.5 m minimum ceiling clearance; 1 m clearance around the rig for service access. • Environmental Conditions: Ambient 10–40 °C; humidity 20–80% non-condensing; dust-free indoor area preferred. • Structural: Level, vibration-damped concrete floor rated for 600 kg; anchor bolt pattern included for securing the base frame. Maintenance and Calibration Preventive Maintenance Schedule: – Daily: Visual inspection of hoses, fittings, and filter indicators; check oil level and temperature readings. – Monthly: Lubricate pump bearings; verify emergency-stop functionality; review alarm logs. – Annual: Complete oil replacement; replace filters; full system leak test. Calibration Protocol: – Flow Meters & Transducers: Calibrate annually using a gravimetric flow bench and dead-weight pressure tester traceable to national standards. – VFD & PLC: Perform software integrity check and firmware updates quarterly; validate closed-loop control accuracy via step-response tests. Spare & Wear Parts: On-site kits include filter elements, seal cartridges, spool-valve O-rings, and relief-valve springs—all designed for quick field swaps without special tools. Software & Data Management The rig’s HMI software—built on a modern .NET 5 architecture—provides an intuitive dashboard displaying real-time pressure vs. flow graphs, temperature readings, and shift-cycle counters. Test recipes are stored as XML files, allowing easy import/export and version control. All run data is archived in an SQL Server 2019 database, searchable by date, batch number, or operator. The software includes an OPC UA server for seamless integration with factory SCADA and MES platforms. Report generation supports multiple formats—PDF for certificates, CSV for raw data, and XML for ERP ingestion—while user-role management ensures secure access to sensitive test results. Conclusion By combining high-precision hydraulic control, comprehensive data acquisition, and flexible software integration, the ARJUN NOVO PST Test Rig offers an end-to-end solution for both production and development environments. Its robust safety architecture and detailed calibration protocols guarantee reliable, repeatable testing over years of operation. Whether deployed on a high-volume assembly line, in a specialized R&D lab, or within service workshops, this rig minimizes warranty risks, accelerates product validation, and elevates overall quality assurance for Power Shuttle Transmission units.
