The Challenge
A division of a major aerospace manufacturer required a reliable method to test and certify critical hydraulic components (valves, cylinders, reservoirs) used in their fighter jets. The client also sought to modernize and automate existing testing processes that had been manual, error-prone, and provided inconsistent reporting.
The Solution
MCE Fluid Power Solutions engineered and built a fully automated test bench capable of testing nine cylinders, seven valves, and two reservoirs. The system eliminated operator variability, standardized testing procedures, and increased confidence in results.
Design and Integration
Through a joint engineering effort with the client, MCE designed and built a test stand capable of testing 18 unique hydraulic components, while integrating a protocol of strict test procedures and specifications.
System Features:
- Fully automated hydraulic and electromechanical test station
- Smart HMI interface for programmable test sequences
- Data acquisition with Excel export functionality
- Monitoring of pressure, leakage, cycles, and reaction time
- Extreme test repetitions (60–70 cycles per step)
- Self-validating, operator-independent routines
Results
Through collaborative efforts with the client, MCE restored the client’s control and eliminated dependency on the component manufacture for maintenance and calibration. The system validated the credibility of components performance through standardized and automated testing. This also greatly improved transparency, reliability, and traceability of test data over their manual testing processes.
As a result of these measures, MCE was also able to uncover flaws that prior testing methods could not detect. The aerospace manufacturer is now positioning this system as standard issue for any country purchasing the fighter jet. Results included:
- Consistent, reliable test outcomes
- Test time savings and improved throughput
- Previously undetectable flaws were uncovered
- Enhanced ability of the client to service international military customers
Conclusion
By standardizing and automating the testing and certification of critical components, MCE’s solution eliminated uncertainty, ensured consistent performance, and revealed issues that traditional testing could not detect. Standardizing testing and certification methods gave the client higher confidence in equipment readiness, shorter delivery timelines, and the assurance that every jet meets the highest standards of safety and performance.
At MCE, we know no two projects are alike. Every solution is tailored to your unique needs.
We go beyond hydraulic and deliver strategic technical solutions that combine engineering, electrical, mechanical, and data systems — all done in-house. Our engineering and execution expertise enables us to retrofit, reprogram, or enhance existing systems for greater reliability, safety, and control in the most demanding environments.