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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Hyd, Distributor Control Valve Rig

 

Fully automated hydraulic distributor control valve test rig designed to perform six different test in a sequence. Test include jerk test, ramp test, play test, overload test still test and lap test. simulating loads up to 1.5 tons.

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