Attitude Test Facility for the LCA Aircraft for M/s GTRE Bangalore. :Top
This consists of a complex integrated engine base, sub-frames and hollow trunnion mounted test bed, with pneumatic lines, hydraulic motors and 7 way rotary joints, Artouse gear boxes, optical encoders, RTDS, Pressure switches, vibrometers etc all operated through an Data Acquisition system. Total power: 500 H.P. ; Hydraulic Power: 320 bar operating pressure with 7 way operational rotary joints; Total weight including foundation:200 tonnes.
• Job involved complicated stress analysis of structural analysis of base frame and mechanical members subjected to vibration at nodal points. Software related testing was done for gauging resonance frequency.
• Closed looped, self gauging Computerised Data Acquisition System. (DAS) was integrated controlling speed sensor, vibration sensors / low control parameters etc.
• The most prestigious Kaveri Engine developed by M/s. GTRE was tested for various parameters under hash conditions of pitching and rolling.
• Engine Acceleration from 1 to 21000 rpm in close to 8 seconds under test conditions.

 

 

Hydraulic Hollow Ram Jacks for M/s. Killick Nixon Ltd.: Top
Design , Manufacture , Supply and Testing (at full load) of Hydraulic
Cylinder(Jack) operating at 600 bar hydraulic pressure , hollow ram type, double
acting for tensioning PC Stressed Wire.
• Import substitute for pretensioning of PC stressed wire
• Full design and development of hollow ram as well as seals and backup rings done by our team of designers.
• Operating pressure 600 bar.

 

 

Coal Screw Conveyor Complete with casing 475 mm Diameter for Cement Plants. : Top
Twin feed coal screw conveyor for coal feeding operation including twin chute for feeder and hopper. Job involved on site modification of control and feed parameters for enhancing capacity of production.
• Close tolerance fabrication and machining of both screw ( fully machined flights) and 1.5 mm clearance between casing and O.D. of flight.
• Capacity calculation required upgradation and modification of auxiliary equipment.

 

 

 

Manufacture of Follax Cooler Beams for Travelling Grate Cooler. : Top
Consist of complicated assembly of fixed beam row 1-7 , LH/RH/Centre Girders all within close dimensional tolerances. Machining of subject job done on
10 metres bed type floor boring machine.
• 3 dimensional scaled models of all beams were made to check alignment and conformance to drawings.
• CAD sheet layouts were made to ensure correct profile and minimum wastage of BQ plates ( ASTM A 516 Grade 70 ) .
• Angular tolerances after assembly checked and interlinking was seen .
• Special lifting arm was made to prevent distortion / damage during transportation and loading.

 

 

 

Water Analogy Test Mechanism. : Top
This system consisted of motor actuated valves, controlling flow parameters through outputs form a 550 HP centrifugal pump set and used a complex pipe laying and valve controls including precise measurement & recording of pressures and flow parameters (using digital output Rockwin flowmeters).
• Computer simulated layout done for piping and flow control.
• Diameter 500 mm + pipe lines with flange joints were used for final side execution.
• Total power driving the 2 stages spit casing centrifugal pump was to the tune of 550 HP.

 

 

 

 

1000 H.P. Vacuum Spin Test Door Mechanism. : Top
This consisted of a set of 3 interfaced locking Door Assembly for sealing the Vacuum Test Rig Facility. Complexities of the job involved large scale operations of structural and pressure analysis.
• Job required visualization and conceptualization of vacuum chamber.
• Sealing of mating doors with full flush sealing rings.
• A Scaled model for the same was made with each individual component.

 

 

 

 

CPSU Test Mechanism. : Top
This facility consisted of a close loop system incorporating design and controls for gearbox lubrication pressure and temperature checks. Integrated aspects of flow and pressure controls and measurements were involved.
• Job included intergation RTDs / Pressure / Flow sensors involved in final testing of the lubrication system.

 

 

 

 

Fabrication of Food Hi-lift for Aircraft Catering Application. : Top
Scissors type hydraulic jacking platform for conveying food to air-craft . Assembly involved hydraulic / Pneumatic integrated work on Tata 1612/48 chassis.
• Design and development of scissors type hydraulic platform with limiting conditions of hoisting etc.
• Assembly drawing for all mating components.

 

 

 

 

Wing Turning Mechanism for Mig -27 LCA for M/s. HAL ( Ojhar) : Top
Design , development, fabrication and commissioning of wing turning mechanism. Complex integrated assembly of hydraulic, pneumatic and electrical components .
• Complete design and manufacture of entire system.
• Hydraulic system could incline the entire loaded wing to a positive / negative 30 degree inclination with a feed back cut off in inching / direct mode.
• Control panel for rotational as well as other functions from one point designed and manufactured.
• Erection and complete test trials done at clients facility.

 

 

 

 

 

 

7 Way Hydraulic Rotary Joint. : Top
to facilitate rotary motion between fixed frame and movable frame . Operating pressure 600 bar with complex internal grooving, hard chrome plating, internal honing and deep hole drilling.
• Import substitute job requiring extremely close dimensional tolerances.
• 7 port / 7 way rotary joint used between fixed and rotating frame.
• Operating pressure 600 bar.