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Facilities Available


High Performance Dynamic Test Centrifuge

The High g environment of the current generation Aerospace Vehicles necessitate the Life Support Technologies to be tested to similar stresses in a controlled & simulated environment before being tested in the actual aerial vehicles. This necessitates the requirement of a high performance Dynamic Test Centrifuge on which the Life Support Systems could be mounted and tested in functional condition. activities.

The High Performance Dynamic test centrifuge has been manufactured on DEBEL specifications. It has provisions to test the life support systems in operating condition and monitor the data on-line, Max Capability 20 g peak at an onset rate of 10 g/sec max, fully computerised, Max Payload 25 Kg, mounting options of payload in '+' or '-' x, y or z axes. It has Pneumatic supply provided through rotary joint and DC power through slip rings and on-line wire-less monitoring of 15 channel data along with g-signature. All possible safety measures are incorporated in the specification.

Hydrostatic Simulator

It enables the assessment of functioning of Submarine Escape Set with the help of instrumented dummy system in a vessel filled and pressurized with water for depths up to 200 m.

Breathing sequence using the gas mixture in the set is simulated in the chamber and gases released at different depths from the breathing apparatus by the submariners are analyzed in the TRIMIX gas analyzer.

Provision of ascertaining the ascending rate of submariner is also provided in this test facility.


Man Rated High Altitude Chamber

Aviation environment exposes the aviators to extremely high altitudes. With the Indian Human Space Program a reality, an environment akin to actual vacuum has become a reality. Hence, the Life Support Technologies being developed needs to be tested in a high altitude chamber having appropriate capabilities.

The High Altitude Chamber is under manufacture on DEBEL Specifications. It will be man rated and being built to PVHO standards. It has been so designed that any of the Life Support Equipment can be tested in functional condition with on-line monitoring of data.

It has the seating capacity of 4 persons in main and 2 in auxiliary chambers. Max altitude of main & Auxilliary chambers are 50000 ft and 100000 ft AMSL respectively, both having operations independent of each other. There is pneumatic compressed air & oxygen supply to each chamber. It has a provision of Rapid Decompression (RD) from 8000 ft to 23000 ft or 21000 ft to 50000 ft AMSL in < 2 sec. There is also a provision to configure the RD from any altitude within a given pressure differential of about 5.5 psi. The functional data is obtained on-line for continuous monitoring.

Test Facility for OBOGS

This test facility is designed for functional evaluation and qualification of On-Board Oxygen Generating System (OBOGS). It has capability to carryout the on-ground and simulated high altitude tests. It consists of vacuum chamber fitted with two high flow rotary vacuum pumps with necessary pneumatic and electronic controls. The functional tests under various simulated conditions carried out on this facility to demonstrate that the system meets the entire design specification requirement in respect of function, operational performance and safety.


Quick Disconnect Coupling Test Rigs

Pullout Test Rig: The tester is designed to test the QDC for positive locking and unlocking force to detach the seat part from aircraft part of QDC which happens during the seat ejection. The QDC aircraft part is mounted in the bottom fixture provided on the rig and the lanyard cable of the seat part is fixed in the upper fixture hook which is fitted to the load cell. The load cell has peak hold facility to record the maximum load during the detachment of the QDC. The movable top beam of the tester is moved up and down by means of a motor whose speed is controlled though a potentiometer.

Pneumatic Test Rig: The pneumatic test rig is designed to carry out the performance evaluation of QDC for its acceptance and qualification. It has pressure and flow controllers with necessary instrumentation for various tests of QDC. It has capability to carryout leakage, flow and pressure drop tests

Demand Oxygen Regulator Test Rig

The functional tests of DOR are conducted in this test rig which is built around a high altitude chamber. The rig is especially suitable for simulating Rapid Decompression Scenarios and positive pressure generated in the DOR at various altitudes. The Unit under test is mounted in high altitude chamber and appropriate valve combinations are chosen to achieve the required pneumatic circuit combinations for carrying out the test as per the QTP document of DOR. Required pressures and flows are applied through the pressure regulators and flow control valves and various functionalities and the leak rates are recorded with the help of the flow meters, pressure gauges. The high altitude chamber simulates MAX of 60000 ft AMSL.

 

Breathing Simulators

Electro-pneumatic Breathing simulator

This pneumatic based test rig has a provision to create various rates of inspirations with an option to set the tidal volume. It is extremely helpful in endurance testing of the breathing systems and assemblies.

 

 


Automatic Breathing Simulator

The automatic breathing simulator is a device which is used for simulating human breathing. It consists of a stainless steel bellow driven by a servo pneumatic system under displacement control. It is intended to follow position demand waveforms which generate air flow / breathing profiles and is controlled from a computer program interfaced to a PC via an Ethernet link. The bellow assembly with a pneumatic actuator propel air / oxygen-enriched air mixtures between pressures of 2 to 1200mbar absolute. It is suitable for placing inside an altitude chamber with altitude upto 50,000 ft AMSL. Various breathing waveforms can be generated with a facility to control and monitor various relevant parameters like flow, tidal volume, breadths per minute, peak flow, rate of change of flow etc. The bellows assembly can be located inside an altitude chamber with the monitoring system located outside the chamber.


Anti-G Valve Test Rigs

This consists of a static test rig in which the acceleration loading on the anti-G valve is imposed in the form of multiple weights and the output pressure is read in the rig. It is also used to measure the leakage

The small test centrifuge has been the backbone of the anti-G valve testing till now. It is a small yet computer controlled centrifuge meant for mounting small weight loads. It has a rotary pneumatic joint for compressed gas supply and on-line data acquisition. It essentially tests the anti-G valve dynamic performance.

High Pressure Test Rigs

The test rig is designed and developed to carry out the pneumatic performance tests of high pressure oxygen system. The test rig is also fitted with an electronic module to indicate the various warnings wrt to oxygen content in the cylinder etc. generated using the electrical signal from the unit under test. All the flow meters on the test rig are mounted on the vertical panel and the control valves and pressure indicators are fixed on the horizontal panel. The unit under test shall be placed on the platform provided by the side of the test rig.



Personal Equipment Connector (PEC) Test Rig

The functional tests on PEC are conducted on two separate test rigs. One is for the evaluation of unlocking force and the electrical continuity between the spring loaded connectors and the second for carrying out the leakage tests. The first one has a PEC test block with DOR-AGV interface for simulating the ejection seat separation. The unlocking force is measured by fitting PEC on the test block and pushing the plunger in the test block with the help of a load cell. The unlocking force can be directly read from the load cell read out. The continuity between the electrical connectors can be read from the display fitted on the test rig.

The second test rig is for measuring leakages which is built around a sealed leak chamber. The unit under test is placed inside the chamber after making the necessary pneumatic connections. Required pressure is applied through the pressure regulators and the leak rates are recorded with the help of the flow meters.

Oxygen Sensor Test Rig

This test rig has been created to test the PPO2 oxygen sensor (OS) designed and developed by DEBEL. It creates a different oxygen concentration gas mixtures and varying OS heater temperatures to characterise the sensing by the OS. The test rig has become very useful in the on-going ILSS program of DEBEL.


ILSSIntegration Test Rig

This is a test rig for comprehensive testing of the ILSS. All the LRUs of the ILSS are mounted on a test platform, connected with the requisite pneumatic system with the output gas supplied to the oxygen mask and anti-G suit of the test dummy and tested accordingly. The breathing simulator is also connected. In this test rig, the normal functions as well as failure conditions are created and the system tested for full functional capabilities.

 

ECU Test Rig

ECU Test Rig is used to simulate various inputs, monitor outputs and to verify the functional specifications of the ECU during normal laboratory tests as well as during ESS Tests. The Test Rig is realized using an Industrial PC with off the shelf available USB modules and an application specific hardware module. The various ECU I/Osare brought to a patch panel / terminal box through which signal monitoring / break in is possible. Salient Features of the ECU Test Rig are:

  • It provides complete interface simulation for the ECU to enable functional testing of the ECU at the Unit level.
  • It has been built around an Industrial PC. This Test Rig contains all the hardware and software components required for testing the ECU interfaces.
  • An integrated GUI is designed to cater testing of different modes of the ECU.
  • The Test Rig simulates all I/O requirements of ECU, so that the ECU can be tested for their stated performance.
  • The ECU Test Rig has provision for display of logged data.

Thermo Gravimetric Analyser

Thermo Gravimetric Analyser (TGA) is an analytical instrument used for the determination of thermal degradation of textiles, rubbers, composites, plastic etc in controlled atmosphere. Change in the mass of the sample is studied while the sample is subjected to controlled temperature programmed ramp either linear or isothermal.

TGA is inherently quantitative; therefore, it is an extremely powerful thermal technique. TGA is mainly used for Thermal stability determination, Material characterization, Analysis of blends and Kinetic and corrosion studies.


Differential Scanning Calorimetry

Differential Scanning Calorimetry coupled with microscope (DSC-M) measures the temperatures and heat flows associated with the transitions of the materials as a function of time (or temperature) in a controlled atmosphere. The microscope coupled with the equipment provides online visual changes that take place during the transition of the material.

DSC-M can be used for- Glass transition temperature, Crystallization / Melting, Specific heat, Oxidative / thermal stability, Reaction Kinetics, Purity.

 

Reactor For Microencapsulation

Micro encapsulation reactor is used for encapsulating Phase Change Material (PCM). The microcapsules in which PCM is encapsulated are coated onto the fabric that finds application in near body thermoregulation.

The reactor can be used for development of microcapsules coated fabrics having Phase Change materials, Mosquito repellents, CW/ BW decontamination agents.


Rotary Vacuum Evaporator

Rotary evaporator is used in chemistry laboratories for the efficient and gentle removal of solvents from samples by evaporation under reduced pressure below their boiling point. The equipment is extremely useful in removing and separating thermally labile solutes dissolved in high boiling solvents much below the boiling point of the solvent.

 

Rf Sputtering Unit for Sensor Materials and Electrodes

Radio frequency (RF) sputtering, is a physical vapor deposition (PVD) method, for deposition of thin films. This involves ejecting material from a "target" which is a source, onto a "substrate" such as a silicon wafer, glass, etc. Its advantages are; (i)Multiple targets can be used for creating multilayer films & doping (ii)Deposition of compound materials such as Oxides and Nitrides, through reactive sputtering. Its applications include; (i)Deposition of sensor material in the form of thin films, (ii)Deposition of metallic thin films for electrodes and other semiconductor devices.


Facilities for FR Characterisation of Materials

Cone Calorimeter

It works on the 'oxygen consumption' principle to evaluate the flammability behaviour of textiles and rubber specimens as per ASTM E 1354/ISO 5660. A total of 16 parameters that affect the burning behaviour of textiles/rubbers/polymers or any organic materials can be obtained.

 

 

Thermal Protective Performance Tester (TPP)

The tester predicts the amount of thermal protection a FR fabric or an assembly of fabrics would provide if exposed to a flash fire as per (ASTM D4108-87). The time required to cause onset of second degree burns can be obtained from the above equipment.

 

 

Automatic Flammability Tester (AFT)

The AFT 45° Flame Chamber automatically measures the flame-spread time (rate of burning) of textile specimens burned at a 45° angle under controlled flame-impingement conditions as per ASTM D 1230.

 

 

 


Lateral Ignition Flammability Tester (LIFT)

The LIFT apparatus is intended to measure the rate of burning of Polymers, textiles, rubbers and plastics as per ISO 1320

 

 


Smoke Tester

The smoke tester is intended for measuring the smoke density and other related parameters.

 

 

 

 

Limiting Oxygen Index Tester (LOI)

LOI is used for measuring the quantity of oxygen required to sustain the combustion of textiles and plastics as per ASTM 2863

 

 

 


Advanced Electro - Acoustic Test Facility


An advanced Electro - Acoustic test facility is intended for evaluating of microphones and earphones while being integrated in the Oxygen Masks and Helmets.

The Electro - Acoustic Test Facility consists of state of art Bruel & Kjaer equipments such as Head and Torso Simulator, Generator module LAN-XI, Power Audio Amplifier and Pulse Electro-acoustic software modules.

Head and Torso Simulator consists of a mouth simulator and two ear simulators. It provides the simulation of the acoustic field around a human head and torso. Performance parameter of Microphones and Earphones such as Output response, Frequency Response, Total Harmonic Distortion and Impedance curve can also be evaluated. The facility is also capable of evaluating Aircrew Helmets & Ear defenders for Noise Isolation characteristics and recording of environmental noise.

 

Instrumented Dummy Test Facility

This facility is used for prediction and assessment of the injury levels due to shock wave produced by bomb blast.

It is meant to be used for developing human response model to mine blast & blast debris and evaluation of various anti mine protective gears.

It shall also be used for various applications where effect due to blast needs to be quantified and protection systems to be developed accordingly. DEBEL has the expertise for the simulation of various protective structures subjected to blast pressure wave and for testing the efficacy of the structure for better structural development.


Reducer And Breathing Bag Test For Submarine Escape Set

This is a DEBEL designed test rig exclusively for the Submarine Escape Suit. The reducer head of the helium/heliox cylinders are tested for its performance by simultaneously connecting it with the breathing bag.

 


Pressure Breathing Oxygen Mask Test Rig

The Pressure breathing oxygen mask is an essential aircrew protective equipment which delivers the breathing gas to the aircrew made available by the breathing regulator of the aircraft. It becomes essential for the mask not to pose additional resistance to the breathing, or cause leakages. DEBEL has designed an automated Oxygen mask test rig that can test the mask for all its pneumatic functions. The test rig has various flow & pressure controllers with solenoid valves. It also has a digital sensor.

The test rig has two head forms to cater to different sizes of the oxygen mask. Once the mask is mounted on the head form, all tests can be completed within 5 minutes by a click of the computer mouse. The test results are presented in a form that compares it against the laid down standards.

Impact Attenuation Test Rig For Aircrew Helmet

An aircrew helmet must be able to prevent head injury provided that the force of injury is survivable. The helmet is expected to attenuate the accelerations imposed on the head. In order to evaluate the extent of impact attenuation, this test rig imposes such acceleration on to the helmeted headform that is instrumented with a 3-axes accelerometer.

The test rig has a motorized winch, a drop arm with magnet running freely on the side rails, a pair of proximity sensor to measure the drop velocity, and a flat anvil mounted on a magnetic base. It is fully automated wherein the variable stress parameter can be set in terms of impact velocity, height of drop or the impact energy. On being dropped, the computer acquires the accelerometer parameters along with other data and presents them in a report form.

In addition to the above the following test facilities are also available:

1

ANECHOIC CHAMBER

2

OPTICAL DISTORTION TESTING

3

GAS CHROMATOGRAPH - MASS SPECTROGRAPH (GC-MS)

4

ELECTRO-CHEMICAL WORKSTATION

5

UNIVERSAL TESTING MACHINE

6

FOURIER TRANSFORM INFRARED SPECTROPHOTOMETER

7

NCD TEST FACILITY COMPRISING:

  1. TOXICITY INDEX (NCD-1404)
  2. SMOKE INDEX (NCD-1410)
  3. LOW OXYGEN INDEX (NCD-1411)
8

LIFE ESTIMATION OF AIR CLEANING FILTER (ATVP)

9

HIGH PRESSURE LIQUID CHROMATOGRAPHY (HPCL)

10

SURFACE AREA ANALYSER

11

UV-VISIBLE SPECTROPHOTOMETER

12

MICROPLATE READER

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