Test Rig

Project Overview

Kpdesign was asked to create a test rig capable of withstanding a 100kN force from a hydraulic cylinder. This rig would be used to validate crucial components of the client’s product.

The Challenge

The rig needed to be strong enough to endure a 100kN load without breaking and function in both horizontal and vertical orientations. It also had to slide one half to another for interface testing and include an instrumentation panel to run liquid oxygen and helium.

Our Solution

We used first-principles calculations in a spreadsheet to quickly determine the right size of steel members, reducing the need for extensive simulations. During detailed design, we monitored how each configuration would be used, focusing on the centre of gravity in vertical mode to prevent toppling. We teamed up with trusted suppliers to select the ideal linear bearings for smooth movement, and we chose fittings that would safely handle liquid oxygen and helium.

Results

Working closely with a certified welder and reliable suppliers, we delivered the test rig on time and within budget. The client successfully validated their key product components using this robust, adaptable rig.

Project Details

Client

Confidential Client (under NDA)

Location

Auckland, New Zealand

Year

2023

Services Provided

Concept Development, Engineering Design, Production

Technologies Used

CAD, Finite Element Analysis (FEA), first-principles calculations, structural analysis, laser cutting, machining, welding, fabrication