- Aerospace Certification: Validates rain-penetration resistance of fuselage seals, canopies, panel joints and coatings per MIL-STD and FAA requirements. - Environmental Qualification: Tests water-ingress protection of avionics bays, cargo doors and fasteners. - Maintenance Training: Simulates rain-light conditions to verify post-repair sealing, drainage paths and water-shed performance.
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Introduction & Purpose The Rain Water Test Rig is engineered to reproduce controlled rainfall conditions over aircraft surfaces, using a total of 82 top-mounted nozzles and 16 nozzles on each side. Its two core test phases are: - Qualification Testing on the prototype, to validate design efficacy, safety margins, life-cycle performance and reliability against both technical and end-user requirements. - Acceptance Testing during bulk production, to ensure every unit meets the governing specs before dispatch, thereby guaranteeing consistent quality and minimizing in-service failures. Structural Overview A full-size GA drawing shows the rig’s detachable twin-tank structure, support frame and mobility system: - Water Tanks: Two 2,000 L PVC tanks sit on a detachable SS 304 support frame. - Frame: Welded SS 304 square tubing (100 × 100 mm base; 50 × 50 mm top), providing rigidity and corrosion resistance. - Mobility: Six heavy-duty caster wheels (7,500 N each) with locks allow easy positioning and secure fixation on the hangar floor. - Adjustability: Side-wing assemblies pivot ±60° to vary spray angle, accommodating different fuselage geometries. Hydraulic Circuit & Flow Path The hydraulic schematic outlines a closed-loop water circuit: 1. Supply from the 2,000 L tanks through a 60-mesh SS 304 strainer. 2. Boost via a Grundfos CM 15-3 centrifugal pump (4 kW/5.36 HP), delivering up to 250L/min at 10 kg/cm2. 3. Main Manifold: 3′′ Schedule-80 uPVC piping distributes flow to top and side headers. 4. Branch Lines: 1′′ uPVC branches feed each SS 304 nozzle (spray capacity 1–2 L/min at 2bar). 5. Return/Drain: Drain valves allow rapid emptying post-test. Key Features & Materials - Comprehensive Nozzle Array: • Top: 82 × SS 304 sprinklers (Ø2 mm holes in 8-place pattern) ensure uniform cover. • Sides: 32 × SS 304 nozzles on pivoting pipes, for both horizontal and 60°-upward sprays. - Precise Control: WIKA 232.50.100 pressure gauge (0–10 kg/cm2) for real-time monitoring; shut-off and drain valves facilitate flow regulation and safe shutdown. - Filtration: 60-mesh filter strainer rated 250 LPM removes particulates, protecting the pump and nozzles. - Robust Construction: • Piping & Fittings: Schedule-80 uPVC (1′′/2′′/3′′) with solvent-welded joints and unions for leak-proof integrity. • Structural Steel: SS 304 tubing resists corrosion in wet environments. - Mobility & Setup: Lockable caster wheels and detachable frame modules allow rapid installation, detachment and transport. Technical Specifications & Performance
