• Design and development of Leading Edge slat actuators (In board, mid board and Out board)
• Leading edge slat are secondary surface control actuators

• Characterization of Consistent Aluminum diffusion layer over thread profile (flank, crest, and root) on the threaded specimen is maintained at 60 – 150 µm, Surface finish less than 1.6 µm and hardness at 300 – 320 BHN.
• Purity, Particle size, Homogeneity of the aluminizing mixture and Hermetic sealing solutions
• Establishment of Aluminization cycles
• Establishment of the heat treatment process

• The capacity of 20 aircraft per charge
• Charging up to 250 bar
• Operational temp -30°C to 50°C
• Up to 5 mins continuous duty cycle reliable tinuous duty cycle reliable

• Design of attachment for turret lathe
• Sphericity (form) – 3 to 6 micrometers
• Surface roughness (Ra) < 30 nano meters

Completed Airworthiness qualification testing of LES Actuators with the following tests

• Vibration Tests
• Arrestor Shock
• Shock – Transit drop (with packing box )
• Shock -Bench Handling
• Humidity
• Altitude
• Acceleration Tests
• Thermal Shock
• Low Temperature Storage and Operational
• High Temperature Storage and Operational
• Endurance and Bottoming
• Pressure Impulse test
• EMI/EMC

• thermal shock test,
• high-temperature performance test,
• low-temperature storage & performance test
• Endurance cycling tests (50000 cycles)
  All tests done at control manifold level and servo actuation system level.

• Low pressure station
  (20 to 200 bar)
  High pressure Station
  (200 to 600bar)
  Pneumatic pressure station
  (2 to 20 bar)
• Operational frequency 1 – 5 Hz
• NI cRIO-9068 embedded controller,
• 5 Pressure Profiles
  (Sine, Square, Saw tooth, Triangle and user defined)

• Repeat leakage test at every 10000 cycles
• Thermal Shock test
• Proof Pressure test
• Burst Pressure test
• Assembly and Acceptance testing of CTTC filters
• Assembly and testing of hydraulic system filters 22 aircraft set (198 nos) in three-phase
• Phase-1: 6 aircraft sets
• Phase-2: 8 aircraft sets
• Phase-3: 8 aircraft sets

• Assembly and testing of hydraulic system filters 22 aircraft set (198 nos) in three-phase
• Phase-1: 6 aircraft sets
• Phase-2: 8 aircraft sets
• Phase-3: 8 aircraft sets

• High temperature storage cum operating & ATP
• Low Temperature storage & ATP
• Thermal Shock test
• Pressure Impulse test
• Burst pressure test

• Acceptance test
• Repeated Assy. test
• Manual operation test
• Pressure cycling test
• Burst pressure test
• Endurance test
• Low-temperature test
• High-temperature test
• Thermal shock test

Force Exciter
Static Load : 5000 N
Dynamic Force: 5000 N
Force spectrum: 1 kHz
Excitation mode: Static + Dynamic
Exciter Design: Single-end

Hydraulic Power supply
Flow : 5 lpm
Working Pressure: 206 bar
Servo valve
Rated flow: 12 lpm
Force Sensor: 2500 kg
Type of signal: Random or Sine
Controller: NI- cRIO real-time hardware

Initially the vibration measurement was carried out on the engine in decoupled condition to know the existing vibrations, when it is supported on jacks. The abnormal vibrations of the order of 69.3 mm/sec was noticed in this condition and the detailed analysis was carried out and the analysis results depicts, the problem was due to 1.2mm run out in the engine stub shaft.

This engine stub shaft run out was resulting into higher unbalance induced vibration.  Finally the stub shaft run out problem was corrected. The existing vibration level came down to 20mm/sec. Further analysis was pointing out to lesser structural rigidity of the based frame. The structural rigidity of the base frame was modified by the OEM to increase the stiffness and rigidity of the structure.  Finally, the vibration level came down to less than 5mm/sec.

Task:   Noise and Vibration Analysis of Motor Cycles by Time Event Analysis, FFT Analysis, 1/3 octave analysis, Order Tracking & waterfall Analysis, Transfer Function Analysis of Motor Cycle Elements to identify the resonant frequencies. All these techniques are used simultaneously to identify improvement areas in the motor cycle.

Results: – We identified major improvement points for reduction of noise emitted from the engine for the customer. In the first instance engine noise level was brought down by 8 dBA

Task: The task involved the noise and vibration measurement of load haul dumper used in underground mining. The noise and vibration measurement of the load haul dumper was carried out as per the test conditions mentioned in the standards (ISO2631-1, ISO6394, and SAE J88).

Result: – Improved design of seat isolators effected with a better understanding of the customer perception in respect of conflicting requirements arising for vibration isolation and damping during dumping operation and vehicle movement on plain ground.

Task: This task pertains to the noise and vibration measurement of transformer under full load condition. The vibration acceleration (ref. 1E-05 m/s2) was measured in 1/3rd octave bands (25Hz to 8kHz) at 4 mounts of the transformer, when the transformer was operating under full load condition. The mean vibration acceleration values are compared with the allowable limit values specified by the NES 537.

Result: – Improved design of transformer base and selection of appropriate low cost vibration isolators based on the measurement results and to meet the compliance of the standards.

Task: The logarithmic decrement & FRF measurements of mild steel solid and riveted beams were carried out in order to find out the natural frequencies & damping coefficient factor of the beams. The measurements were carried out on mild steel beams in cantilever condition.

Result: – Improve the of riveting process while joining the two mild steel beams and maintain the equal space between the joints to achieve the good damping value. The higher damping and stiffness values are noticed in composite material.

Task: This task pertains to the Noise, Vibration and Thermography measurements carried out on intaglio printing machines.  The measurements were carried out during printing and impression cylinder off condition to assess bearing condition of the plate cylinder and impression cylinder bearings.

Result: – Improved the life of bearing of printing drum by measuring the temperature and vibration on the printing drum during maximum printing condition (10000 sheet per Hour).

Task: The task involved dynamic balancing of the USUPTM Spindle assembly. The vibration measurements were carried out on spindle to know the magnitude of unbalance-induced vibration. The vibration severity level was measured in the frequency band of 0-1kHz.

Result: – To achieve the surface roughness of less than 1 nanometer, we balancing the spindle to less than G0.4 grade. We achieved the balancing grade less than the G0.1 grade.

Task: Identification and ranking of different noise sources of Tractor

Technique: Measurement of sound intensity over a surface of a complex and multiple noise sources.

Result: The investigation led to redesign of engine and transmission element assembly features. Predominant noise source components in the tractor are identified and ranked to help in product development to reduce the noise level further in order to meet the Environmental Norms.

Task: The task involved measurement of structure borne noise and sound intensity measurement of Kochi HVAC Unit. The measurement was carried out at different operating condition as per customer requirement and the results are given below. The sound intensity measurement were carried out as per ISO 9614-2, when the VAC Unit running in full cooling mode (all the elements are running)

Result: The investigation led to know the maximum noise generated by the HVAC unit element. Predominant noise source components in the HVAC are identified and ranked to help in product development to reduce the noise level further in order to meet the Environmental Norms.

Task: The task involved measurement of ground vibration at inside the underground clean room lab area. The ground vibration due to movement of traffic, men, machine and other environmental activities were measured to know the existing ground vibration levels.

Result: The ground vibration measurement values give the selection of isolators for the machined to be installed at the particular area. Before installing any high precision machine like CMM, Diamond Turning and any Metrology equipment we should measure the existing ground vibration levels to select proper isolators

Task: The task involved the structure borne noise tests of a HVAC Unit for Kochi Metro. The structure borne noise carried out on the seat supports and handle for passenger support to know the vibration level experienced due to the running of HVAC unit inside the coach.

Result: The ground vibration measurement values give the selection of isolators for the machined to be installed at the particular area. Before installing any high precision machine like CMM, Diamond Turning and any Metrology equipment we should measure the existing ground vibration levels to select proper isolators

Task: Balancing of the propellers was carried out on SCHENCK R2BU Dynamic Balancing Machine. The Propeller was mounted on the mandrel made for the purpose of balancing. The Mandrels were first balanced to a quality grade of better than G0.4 (as per ISO-1940). The propeller was then mounted on the mandrel and balanced to a quality grade of better than G1 grade.

Result: The dynamic balancing of propeller to less than G1 grade for the better performance during the application.

i. Testing as per MIL-PRF-5503F.
ii. Test frequency of 5 Hz.
iii. Total No of cycles 1,00,000 cycles
a. (50000 Extend and 50000 Retract)
iv. Peak pressure of 240 bar.

1. Overall performance of the self cleaning filtration system used in locomotives of the Indian Railways

Pressure impulse testing of indigenous Ti-Tubes as per SAE ARP 1383.

i. No of Cylinders: 6 nos.
ii. Dead volume of each cylinder: 0.247 l
iii. Frequenc: 5 cycles/sec
iv. Impulse peak pressure: 170 bar, 200 bar & 230 bar.
v. Rate of pressure rise: 13,790 bar/sec to 20,684 bar/sec

• Design and development of Leading Edge slat actuators (In board, mid board and Out board)
• Leading edge slat are secondary surface control actuators

• Characterization of Consistent Aluminum diffusion layer over thread profile (flank, crest, and root) on the threaded specimen is maintained at 60 – 150 µm, Surface finish less than 1.6 µm and hardness at 300 – 320 BHN.
• Purity, Particle size, Homogeneity of the aluminizing mixture and Hermetic sealing solutions
• Establishment of Aluminization cycles
• Establishment of the heat treatment process

• The capacity of 20 aircraft per charge
• Charging up to 250 bar
• Operational temp -30°C to 50°C
• Up to 5 mins continuous duty cycle reliable tinuous duty cycle reliable

• Design of attachment for turret lathe
• Sphericity (form) – 3 to 6 micrometers
• Surface roughness (Ra) < 30 nano meters

Completed Airworthiness qualification testing of LES Actuators with the following tests

• Vibration Tests
• Arrestor Shock
• Shock – Transit drop (with packing box )
• Shock -Bench Handling
• Humidity
• Altitude
• Acceleration Tests
• Thermal Shock
• Low Temperature Storage and Operational
• High Temperature Storage and Operational
• Endurance and Bottoming
• Pressure Impulse test
• EMI/EMC

• thermal shock test,
• high-temperature performance test,
• low-temperature storage & performance test
• Endurance cycling tests (50000 cycles)
  All tests done at control manifold level and servo actuation system level.

• Low pressure station
  (20 to 200 bar)
  High pressure Station
  (200 to 600bar)
  Pneumatic pressure station
  (2 to 20 bar)
• Operational frequency 1 – 5 Hz
• NI cRIO-9068 embedded controller,
• 5 Pressure Profiles
  (Sine, Square, Saw tooth, Triangle and user defined)

• Repeat leakage test at every 10000 cycles
• Thermal Shock test
• Proof Pressure test
• Burst Pressure test
• Assembly and Acceptance testing of CTTC filters
• Assembly and testing of hydraulic system filters 22 aircraft set (198 nos) in three-phase
• Phase-1: 6 aircraft sets
• Phase-2: 8 aircraft sets
• Phase-3: 8 aircraft sets

• Assembly and testing of hydraulic system filters 22 aircraft set (198 nos) in three-phase
• Phase-1: 6 aircraft sets
• Phase-2: 8 aircraft sets
• Phase-3: 8 aircraft sets

• High temperature storage cum operating & ATP
• Low Temperature storage & ATP
• Thermal Shock test
• Pressure Impulse test
• Burst pressure test

• Acceptance test
• Repeated Assy. test
• Manual operation test
• Pressure cycling test
• Burst pressure test
• Endurance test
• Low-temperature test
• High-temperature test
• Thermal shock test

Force Exciter
Static Load : 5000 N
Dynamic Force: 5000 N
Force spectrum: 1 kHz
Excitation mode: Static + Dynamic
Exciter Design: Single-end

Hydraulic Power supply
Flow : 5 lpm
Working Pressure: 206 bar
Servo valve
Rated flow: 12 lpm
Force Sensor: 2500 kg
Type of signal: Random or Sine
Controller: NI- cRIO real-time hardware