Test bench for aerospace components

Implementing projects for the aviation industry requires years of experience, a comprehensive approach, and versatile knowledge.

PONAR Wadowice designed and manufactured a test bench whose task is to supply appropriate pressures to the test chambers of the final product—actuators—as well as the chambers of a special system based on a servo valve for fuel injection.
The tested elements are used in the aviation industry.

The system was designed so that it can simultaneously supply 6 different pressures for static tests and dynamic tests with a frequency of 1.6 Hz for one chamber, with a repeatability ranging from 100 thousand cycles to 2 million cycles.

The pressure range in which the system operates is from 0.6 bar to 350 bar.

The test bench was designed taking into account the very high standards set by Woodward, such as:

– very high accuracy and repeatability of performed tests – measuring transducers with an accuracy of 0.01%, pressure control servo valves with high control precision

– high health and safety requirements applicable to dynamic tests up to 350 bar – protection of operators against hydraulic shock in the event of component failure or destruction

– noise generated below 75 dB – thanks to the designed cabin acoustically insulated with special acoustic mats, we achieved a result below 65 dB

– test cabin ventilation system in order to maintain an air temperature of 25 to 30⁰C – ensured by the use of appropriate fans and ducts forcing air circulation

– heat emission – inside the oil system, the temperature does not exceed 31 to 35⁰C – maintained thanks to a specially selected cooling system using an intermediate medium.

The tests take place in a safe chamber, in an automated cycle.
Using servo valves, the test bench executes pressure profiles up to a maximum pressure of 350 bar according to a given characteristic and checks the tested elements by comparing them to a standard. The drive for the working functions is provided by a variable displacement piston pump driven by a 22 kW motor.
Two bladder accumulators with a nominal capacity of 3 dm³ are installed in the system to stabilize the pressure initially delivered to the proportional reducing valves.