Specializing In

  • Test Rigs 

  • Inspection Machines 

  • Instrumentation for product testing

Developing Test Rigs for a wide range of industries including Sports, Automobile, Oil & Gas, Universities. We design According to Your Requirements

 

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About Us

ABOUT US
Test rig

 

Hybrid Engineering specialize in the design and development of high performance innovative Test Rigs and Inspection Machines for wide rage of industries including automotive, oil & gas and sports.

We provide the finished product on time, in full and on budget, offering full onsite support. We also provide services related to product testing through instrumentation.

OUR TEAM
Test rig

 

Hybrid Engineering has a team of dedicated engineers, taking pride in delivering high quality products cost effectively. We have a team of dedicated engineers from graduates to PhDs working on engineering solutions, committed to providing excellence in engineering.  

OUR SOLUTIONS

Test rig

 

Our in-house Electronics team provide packages of high response control fully supported by our in-house console build capability, combining this with our hydraulic, pneumatic, instrumentation and fabrication expertise to provide fast response demanding test rigs and multi-gauge inspection machines.

Products

We Design and Develop customized solutions for our customers.
We have expertise in Mechanical, Electrical and Instrumentation Engineering. Having proficiency in Data acquisition systems and sensor technology gives us the edge to develop cost effective complete solutions 

 

Test Rigs & Test Benches

Some of the delivered customized test rigs made according to individual manufacturer specifications for testing and approvals of various products    

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Transmission Shift Gear Test Rig 

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Fully automated hydraulic operated test rig for performance and endurance test of shift gears, designed for automotive vendor according to Japanese OEM specification. A number of tests can be performed on this rig including load ramp test, strain test and dynamic test including fatigue and vibration test up to 15Hz and 10,000 N load.

Hydraulic Lift Pump Test Rig

This high pressure test rig can generate pressures up to 400 bar at 30 ltr/min and pressure pulse up to 350 bar for pulse range from 0.05 to 0.2 seconds. A number of pump parameters are recorded including heat generation, power consumption, vibration, dynamic pressures, etc.

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Endurance test rig for tractor hydraulic lift pump. Designed and developed for automotive OEM according to MF UK specifications. 

Automated Hydraulic Steering Pump Test Rig

                  with Report Generation

Fully automated hydraulic steering pump test rig running the test procedure defined by the OEM with a click of a button. The tests lasts for about 20 minutes going through the complete test program comprising of various speeds and pressures. At the end of the test a report is generated with all the key parameters recorded.

Some of the key parameters monitored and controlled include pump speed, flow rate, oil pressure, oil temperatures, vibration and drive torque. 

Vibration Test Rig 

For Military applications

 

 

This test rig is specially designed for testing military equipment. The test rig can generate a wide range of 'g' values. Advanced drive mechanism and feedback system are used to generate various frequency and amplitude vibrations.

 
 
 
 
 

Mercedes Benz Engine

 

This project was delivered to a US oil company, instrumenting Mercedes Benz engine for component performacne evaluation.

 

Tappet rotation is one of the key tribological parameters that play an important role in component wear. Lack of available techniques has discouraged researchers from performing such studies on real production engines. In this project, a novel experimental technique has been developed that allows the measurement of tappet rotation speed on any engine having direct acting tappets. This unique method does not require any changes or modifications to the components or engine itself. Using this innovative technique, for the first time, all the tappets of a single camshaft have been instrumented and tappet speed was measured at different operating conditions verifying that not all the tappets behave in the same way. Experimental results clearly showed that all tappets do not respond to the change in lubricant viscosity and the direction of tappet rotation may be one of the factors influencing the performance.

Audi Engine

Tribo-test

 

This was a consultancy project for a European Oil giant. The project was to instrument the Audi engine with state of the art sensors to understand the effect of egnine operating conditions on component performance. The engine was instrumented in such a way ensuring the components operate under original environment with no modification to the components under investigation. This is a confidential project and thus the details cannot be revealed.

Toyota Valve-train

 

This work was carried out for a European oil giant, looking at the effect of lubricant formulation on engine performance.

 

Real production engine employing end pivoted roller follower valve train has been instrumented to investigate the effects of engine operating conditions, lubricant rheology and chemistry on the sliding of valve train roller followers. The test results showed that due to shear drag it was not necessary for roller rotational speed to increase with camshaft speed. The lubricant viscosity played a key role in the roller slip at lower temperatures however at higher oil temperatures negative slip was also observed indicating that component inertia and internal friction have a role to play in roller slip. The results also clearly showed the impact of viscosity improvers on roller slip. The design and development of experimental set up, instrumentation and test procedure was the objective of this work.

Cummins HDD

 

In this project new systems have been developed that allow measurements of a number of parameters vital for evaluating the cam/tappet interface. One of the main reasons for developing these techniques was to allow the study of the cam/tappet interaction in its original environment. The experimental system developed allows the measurement of cam/tappet friction on a gear-driven pushrod valve train configuration. With the help of a recently developed new technique for measuring tappet rotation, the tappet speed can also be measured along with the oil film thickness at the cam/tappet interface using the capacitance technique. All the three main parameters – friction, oil film thickness, and tappet rotation – have been measured for a range of engine conditions and lubricant types. The experimental techniques used were developed in such a way that the modifications had no detrimental effect on the cam/tappet performance.

 

Engine Bearing Test Rig for Bearing Load

        Capacity and Wear Measurement

Developed engine bearing test rig for measuring friction and wear. Resistivity technique was implemented to measure the wear rate and inline torque transducer for instantaneous friction. Automated loading mechanism was used to calculate bearing load capacity.

Hydraulic Reaction Floor Test Rig 

For Civil Engineering applications

 

 

This test rig is specially designed for Civil Engineering Institute for testing of concrete columns and beams under controlled conditions using advanced Electro-Hydraulic Control Valves, cDAQ System and Vector drive mechanism. Both Monotonic and Cyclic Loading can be applied up to 40 tons. User can defined different load ramp values. All the data including the Load, LVDT x 3 and Strain Gauges x 8 are synchronized and logged for detailed analysis.

Engine Head Test Rig

 

This state of the art test rig was developed to conduct test on engine head for valve train performance. The advanced data acquisition system and series of sensors allow monitoring of all the key parameters needed to evaluate the performance of valve train components. The Vector flex motor drive control system coupled with 720 ppr encoder feedback system makes the rig suitable for simulating any type of drive cycle required. The independently driven oil delivery system has a dual control mechanism, constant speed and constant pressure. Plate type heat exchanger with the oil heating and cooling system gives the flexibility to run the rig at near subzero to 125 degree centigrade. Tappet rotation, roller slip ratio, oil film thickness at cam/tappet/roller interface, camshaft average as well as instantaneous friction torque are some of the parameters that can be measured using this test rig. 

Hydraulic Actuator Test Rig

 

Developed fully automated hydraulic actuator test rig for hydraulic cylinder manufacturer for end of line quality testing. A series of advanced control valves combined with intelligent algorithm measure the key performance parameters. 

 

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Axle Test Rig

 

The axle test rig is designed to perform endurance and torsional fatigue test on stub axle and drive shafts. The test rig incorporates hydraulics, electronics, mechanics and state of the art data acquisition systems combined with in-house software.

The test-rig has been specially designed
for a tractor OEM according to their specifications

 

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Inspection Machines

Specially designed Automated Inspection Machines with state of the art software and data acuisition systems for the most precise readings

Automotive Brake Disc Quality Inspection Machine

Customized Brake Disc Inspection Machine developed for Auto OEM at a fraction cost of Imported machines with higher accuracy. This inspection machines measures 15 different parameters. The accuracy of crucial parameters is more than a micron. The machines comes with an advanced user friendly software. 

Vertical Balancing Machine for up to 25KG and

                     40cm diameter parts

Advanced data acquisition system, sensor technology and precision drive mechanism are used in the vibration analysis to assist in the balancing process. The vibration level measured at the rotating speed frequency is used as an indicator of the amount of unbalance.  The location is determined by measuring the phase. Phase, (the relative motion of one part of a machine to another) is measured by means of pickup sensor and counter chip, triggered by a photocell.

Engine Blowby measurement system

 

 

One of the most challenging parameters to measure accurately in engine testing is engine blow-by. The blow-by flow rate of engines is very low and thus is difficult to measure through conventional means. Special techniques are used to measure such limited flow rates. 

 

Engineers designed and developed Engine Blow-by Monitoring System with the flexibility to tailor the user interface according to the customers requirements. This system utilizes the advanced embedded system coupled with sensitive flow system. The in-built advanced DAQ system logs the data for analysis, validates and performs signal conditioning. The data is then displayed on the screen in a user friendly manner.

 

Two portable versions have been developed:

Model RAM-BB1 is a portable plug and play system which can be connected to any laptop or computer through usb port.

Model RAM-BB2 is standalone system with built-in panel pc specially designed for Field Applications.

 

Our system received the best Automotive Innovation Award in 2013.

Synchronized Engine Manifold & In-Cylinder Pressure Measurement System

Synchronized measurement of inlet manifold, exhaust manifold and combustion chamber pressure measurement for all 4 units for combustion tuning to improve engine performance and emissions.

 

One of its kind developed for tractor OEM.

 

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Leak Detection System for Radiators

 

 

Leak Detection System for Radiators was especially designed and developed for Radiator Manufacturers. This system is adopted to replace the conventional wet testing where the radiator is pressurized and dipped in water tank for visual detection of leak. The drawback of such method is the water scale marks left on the product after the completion of the leak test. One of the main advantage of using our system for leak detection is that the product is shipped in mint condition with no scale marks on the product.

 

Based on the sensitivity selected by the user, one of the three techniques of measuring leak is adopted for greater accuracy. The leak is detected through pressure decay, pressure differential and air mass flow rate.  

 

The system can be connected to a PC via usb port. User friendly software gives the user complete control. Leak size and sensitivity can be adjusted with a click of a button. The system logs the data and continuously monitors the total number of pass-fail units. 

Inprocess Grinding Gauge

 

The in-process grinding gauge measures shaft diameter during the part grinding process. The gauge, together with the associated data-acquisition system exchanges information and signals with the grinding machine in
order to maximize performance and achieve the desired results. The gauge automatically monitors the part diameter while grinding in order to control finished part size upto the required diameter.

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Special Projects

 Specially designed testing chambers and mechanical marvels custom built according to requirements and standards

Engine Test Cell

 

 

Pakistan's first engine test cell was designed and developed at the client's premises using state of the art technology. The engine test cell comprises of:

  • Drive-by wire mechanism.

  • Eddy current dynamometer.

  • Throttle control mechanism, of same spec used for testing F1 engines.

  • Pneumatic control engine start/stop mechanism.

  • Fuel conditioning unit, suitable for Euro testing.

  • Dual flow control cell ventilation system capable of generating both positive and negative pressures. System also includes electrical actuated damping system.

  • Water cooling system for the engine and dynamometer.

  • A range of sensors for monitoring complete engine performance.

  • Multi-screen computing system for the control and monitoring of the complete test cell and engine. It is a complete centrally controlled system.

  • State of the art emission analyzer coupled with the test cell control system.

  • The system is controlled through modular based advanced data acquisition system. 

Wide range of tests can be conducted in the test cell including Durability test, fuel and lubricant consumption test, engine friction test, Emission tests including 4-8 mode test, etc. Also a range of drive cycles can be simulated in this test cell.

Engine Dyno Control System

 

Cost effective engine dyno control system was designed and developed for engine OEM for their production test bed. The system was designed according to the customer's requirement. A user friendly interface, gives complete control to the operator for testing engines. This system monitors limited channels enough to monitor engine performance.

 

Channels include:

  • Oil pressure

  • Coolant temperature

  • Engine speed

  • Engine torque

 

A number of digital trips have been introduced for safe operation of the system. High accuracy has been ensured through 14 bit data acquisition system and advance signal conditioning units. This system is modular based and thus is easy to maintain. Modular based system also allows easy up-gradation for further use. 

 

"Designed precisely according to the customer's requirements, ensure cost effective solution with ease of maintenance"

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Electric Vehicle

 

The electric car was designed and developed for a company in Karachi. It is a three wheeler electric vehicle capable of speeds up to 50Km/hr. It can travel at a distance of up to 70km in a single charge. The charging time is approximately 6 hrs and is designed for three persons. The vehicle is made of fiberglass strengthened with lightweight aluminum frame. The car is powered through DC motor via the rechargeable batteries and has a combined power of 1500 watts. 

 

Complete road tests was carried out, based on the US standards. The complete vehicle was designed according to the customer's requirements  

End Of Line Engine Test Bed

End of line engine test bed for testing of production engines has been custom built according to OEM specifications. A number of key parameters are measured for real time performance evaluation and final checks.

Ease of Operation and maintenance after services combined with the cost effectiveness makes this test bed one of the most reliable test beds. 

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