Universal Hydraulic Test Rig - Automated Multi-Station Hydraulic Component Testing System

Details

Introduction
The Universal Hydraulic Test Rig from Neometrix Defence is a turnkey, laboratory-grade platform engineered to replicate real-world hydraulic service conditions for comprehensive evaluation of pumps, motors, valves, cylinders and check valves. Leveraging over two decades of specialized design and manufacturing expertise, this rig reproduces precise pressure, flow, temperature and dynamic
transients to validate performance metrics such as volumetric efficiency, leakage rates, response times and mechanical integrity and generates certification-ready data sets for R&D, quality assurance and predictive maintenance.

Key Features
1. Multi-Component Testing: Supports pumps (piston, gear, vane), motors, valves NG6–NG32, cylinders to 4.6 m & check valves.
2. High-Pressure & High-Flow Capability: Dual 250 kW pumps deliver up to 350 bar at 600 LPM, plus 5.5 kW cooling pump at 250 LPM@10 bar.
3. Precision Filtration & Cooling: Duplex/simplex β ≥ 200 filters and SS-304 plate heat exchangers maintain ISO 4406 cleanliness & ±2 °C.
4. Automated Control Suite: Siemens S7-1500 PLC with Comfort Panel HMI and pre-loaded recipes enable fully automated testing & logging.
5. Modular Test-Bed Design: Three independent stations share a common reservoir; each has its own control panel & emergency stop.
6. Comprehensive Safety & Compliance: Emergency stops, over-temp/overflow sensors & guards meet ISO 12100 and relevant DIN/BS standards.

Technical specification

  

    

      
System Element
      
Specification
    
  
  

    

      
Reservoir
      
SS-304; 1 200 L; 1500 × 900 × 1000 mm; 1″ CS drain valve; ISO VG46 fluid
    
    

      
Level Indicator
      
700 mm borosilicate gauge; SS-304 wetted parts; 10 bar, 80 °C max
    
    

      
Temperature Gauge
      
4″ dial, 0–150 °C; 500 mm stem; SS-304; ±1% accuracy
    
    

      
High-Pressure Pumps
      
2 × 320 LPM @ 350 bar; 250 kW, 1450 RPM IE3 motors
    
    

      
Recirculation Pump
      
250 LPM @ 10 bar; 5.5 kW, 1440 RPM motor
    
    

      
Safety Relief Valves
      
Cooling loop @ 10 bar; main circuit relief @ 400 bar
    
    

      
Filtration
      
Duplex return & simplex pressure filters, β ≥ 200; magnetic drain plugs
    
    

      
Piping & Fittings
      
SS-304 tubing, DIN-rated flanges; vibration-damped hoses
    
    

      
Control Voltage
      
24 V DC for solenoids; 0–10 V / 4–20 mA for proportional valves
    
    

      
Electrical Panels
      
Central MCCB; IP54 PLC/HMI enclosures with cooling fans
    
    

      
Data Acquisition
      
16-channel 24-bit; up to 10 Hz sampling; CSV/XML output
    
  


Applications
• R&D & Qualification: Characterize new hydraulic designs under simulated extreme loads and temperatures; generate certification reports.
• Production Quality Control: Batch testing to verify tolerance compliance and detect early failures; reduce cycle times with automated acceptance routines.
• Maintenance & Overhaul: Condition-based diagnostics for internal wear and performance drift; endurance cycling for recertified components.
• Education & Training: Hands-on fluid-power experiments covering efficiency mapping, dynamic response and failure analysis.

Construction & Materials
• Corrosion Resistance: All wetted parts (tank, piping, tubes, fittings) are SS-304 stainless steel.
• Precision Machining: Pump manifolds and valve bodies from dual-certified stainless alloys; leak-tight assemblies.
• Structural Integrity: Mild steel skid with anti-corrosion epoxy coating; rubber isolators for vibration damping.
• Standard Compliance: Pressure parts to DIN 24342/ISO 6162; instrumentation to ISO 4406 cleanliness codes.

Test Bench Configuration & Automation
Pump Station
• VFD control (vector mode) for 300–1450 RPM; quick-change displacement manifolds.

Cylinder Station
• Servo displacement meter; stroke-position encoders for multi-position leakage and cushioning.

Valve Station
• Conversion plates for NG-series mounting; integrated flow meters and transducers for dynamic tests.

Automation Suite
• Siemens S7-1500 PLC, Profinet I/O; Comfort Panel touchscreen for test setup, execution and safety interlocks.
• Test recipes: save, clone, export; automatic data logging and report generation.

Testing Capabilities & Parameters
1. Hydraulic Pump Tests
• Performance Mapping: P–Q, P–η and Power curves across 300–1450 RPM.
• Hydrostatic Integrity: Internal leakage and burst testing up to 400 bar.

2. Hydraulic Motor Tests
• Torque-Speed: Torque vs. speed under variable load.
• Start-up Diagnostics: Stall/break-away torque; inrush current profiling.

3. Valve Tests
• Functional & Leakage: Up to 315 bar; response times < 20 ms; flow vs. command ± 1%.
• Dynamic Characterization: Step response, null bias, hysteresis and fail-safe conditions.

4. Cylinder Tests
• Multi-Position Leakage: Rod-end, cap-end, intermediate strokes with 0.1 mm resolution.
• Endurance Cycling: Up to 1 000 cycles/hour at 315 bar, 180 LPM.

5. Check Valve Tests
• Cracking Pressure: ± 1 bar accuracy.
• Reverse-Flow Leakage: ≤ 0.5% of rated flow at 90% cracking pressure.

Conclusion
The Neometrix Universal Hydraulic Test Rig sets a new industry benchmark by fusing rugged SS-304 construction, high-precision instrumentation and an advanced automation suite. From prototype R&D and OEM production lines to maintenance workshops and academic labs, it delivers exhaustive test coverage, repeatable results and full data traceability. Safety-certified and built with globalstandard components, this rig ensures reliability, simplifies spares management and accelerates time-to-market—ultimately enhancing hydraulic component quality, reducing downtime and driving innovation across diverse fluid-power applications.