Test Bench Design

Test Benches Design

The applied principle of end-to-end test rig design makes it possible:

create digital models of the test rig and system, the test control system;
simulate the testing process on a virtual polygon to determine the operating parameters, limits and conditions;
adjust the test rig design and test program based on the results of simulation.

The work of the design bureau begins with the study of the test object: its structural design, characteristics and features of operation are considered. The behavior at different modes of operation and design loads are simulated.

1D simulation of the test rig implies the elaboration of its possible designs and their evaluation on the basis of simulation. The components included in the test rig are combined with the control system, which enables the verification of control algorithms and system characteristics. If necessary, prototypes of test rigs or their components are created.

The hydraulic system of the rig is designed based on the efficiency of the assigned tasks and in accordance with the concepts of portability, ease of maintenance and increased operational reliability.

Based on strength calculations and kinematic interaction of elements of spatial and load-bearing structures of the rig, a 3D model is designed.

Electrical diagrams are created depicting the electrical components used and the connections between them. After that, device models are transferred to 3D design software for placement in control cabinets and on the rig structure, which allows the devices themselves, power and control cables to be placed correctly based on electromagnetic compatibility and the necessary protection against mechanical damage, as well as ergonomics of assembly and system operation.
The base of standard electrical components allows you to configure the connections between the elements for the effective implementation of the control system. For testing the control cabinets, simulators of sensors and actuators are used connected to the corresponding channels of the control system.

When developing control systems, we rely on the test algorithm. A test rig model is created, uploaded to the HIL-simulator and simulation of the test rig operation and debugging of the control system is performed. At this stage the performance of all test rig systems is checked, the test rig design and test program are corrected.

In the software, special attention is paid to the development of an interface convenient for the group of test engineers working on a given test rig and depending on the type of tests. It is possible to set the testing algorithm, which allows adjusting the possible loading modes.