Damper and Durability Testing
project name

Damper and Durability Testing

For the Light Rail Industry


Independent validation and verification of fluidic damper for the light rail industry.

CaseStudy9Problem Statement
Ingenium Aerospace was asked to create, execute and document a validation testing program which entailed performing independent product integrity testing of the customers’ stabilization damper products to ensure they would satisfy the punishing demands of the light rail industry. Demands include long life, high duty cycle, temperature extremes and harsh environmental conditions. In addition, the test station needed to be universal and able to test the entire family of products offered in different sizes and performance ranges.

Ingenium Aerospace designed, developed, and maintained an automated test cell which could test the product across a wide array of variables including loads, speeds, frequencies, cycle count, and duty cycle. Ingenium’s test engineering programmed the automated test cell to include continuous data acquisition of critical performance results as well as fault monitoring and reporting. Utilizing upper and lower control limits, the cell could instantaneously interrupt testing in the event of a fault and send out notifications that the automated testing required technician intervention and support. Ingenium’s technical staff created a custom graphical user interface (GUI) for ease of use by our technicians. This GUI allowed for quick switch-over times between different products within the product family. Tens of millions of cycles were accumulated on a variety of damper products.

Results & Outcome
Ingenium Aerospace successfully verified and validated the customer’s product family as requested. Throughout the course of testing, the Ingenium product engineering team provided a technical assessments and recommended product enhancements if a specific product within the product family under-performed to the expected levels.  Implementation of the recommendations increased the robustness of products, allowing the dampers to fully satisfy the expected performance. This was an essential activity to further validate the customer’s product, allowing them to expand their product offering throughout Europe.