Coventry-based NDE Clarke Pitchline has created a novel multi-purpose electro-pneumatic test rig for the end-of-line testing of critical control assemblies and valves for fighter and trainer jets
Initially developed at the request of Safran, the fully automated test rig integrates several processes into a single operation and can deliver ±0.25% accuracy in pressure and flow measurements.
Fully portable for use at numerous locations within Safran’s sites to optimise workflow, the new rig requires standard electrical power and a standard compressed air supply, and is suitable for factory environments and on-apron ground support test roles.
It has halved the test area footprint and cut the time to test a single unit by over 75%, reducing individual test cycles to 9 minutes. The new rig has also deskilled the process, enabling more team members to use it, optimising output and efficiency.
Testing was previously conducted on multiple ‘legacy’ test fixtures and required a skilled, experienced operator to oversee the process. The previous, larger testing module was limited in where it could be used because the high-pressure air supply was located outside the main factory footprint.
The controls and data acquisition (DAQ) functionality for the new rig were developed in-house by NDE’s engineering team at its Coventry headquarters.
Some of the test schedules involve high air pressure ‘proof pressure’ testing, so NDE designed a fully integrated and robust safety system with appropriate SIL-rated hardware and control logic. The existing equipment in service relied on ‘grandfather rights’ and a very limited safety inspection scheme.
This represents a major upgrade on the legacy test equipment, which required detailed operator understanding of the risk control processes. Traceability has also improved, with the new system automatically recording results for audit purposes.
The system has decreased the risk of foreign object and debris (FOD) ingress through its novel design, which incorporates tightly fitting components.
Chris Edgington, director at NDE Clarke Pitchline, said, “This project for Safran clearly demonstrates our unique pedigree and prowess in meeting the exacting testing needs of the aerospace sector.
“Bespoke to a series of current and legacy aircraft control valves which the customer wants to test, the new rig has drastically improved test reliability uptime compared with a previous manual rig, which was more challenging to calibrate and prone to human error.
“Meanwhile, intelligent packaging and pneumatic and electrical process control have allowed multiple test schedules under one system, which can be supported and amended for future test schedule updates.”
