To meet demanding altitude testing for advanced fighter laser components, a major aerospace manufacturer required rigorous cold soak testing. ACS delivered a custom, automated liquid nitrogen dewar system designed for cleanroom compliance and maximized efficiency.
A major aerospace manufacturer developing advanced laser components for sixth-generation fighter aircraft required rigorous cold-soaking tests to ensure they can withstand extreme altitude testing conditions in severely cold environments.
The project demanded a liquid nitrogen dewar system test system that could operate within the strict parameters of a Class 5 cleanroom environment. The system needed to accommodate components of varying sizes and masses while optimizing cost efficiency and cycle times for the necessary cold soak testing.
The company first attempted to repurpose an older liquid nitrogen tank system. The manual system lacked proper sizing calculations, automation, and cleanroom compatibility. As the limitations of their makeshift solution became apparent, the global aerospace manufacturer engaged ACS to design and build a custom-engineered cold-soak test system capable of meeting demanding altitude testing standards.
ACS teams designed and built a fully automated liquid nitrogen dewar system test stand featuring two stacked baskets that work independently, allowing operators to use one basket for smaller components or both baskets simultaneously for larger test loads. Using Acselerant™ software, this flexibility enables efficient soak testing of various component sizes and masses while minimizing liquid nitrogen consumption.
Through collaboration with the manufacturer to refine the test system requirements, ACS engineers produced a design that integrated advanced automation features, including:
They also integrated a variety of safety features into the automated liquid nitrogen management system, such as oxygen monitoring, ventilation controls, and magnetic locks that prevent operator access during unsafe conditions.
The manufacturer wanted to place the liquid nitrogen cold soak testing tank in one of its ISO Class 5 cleanrooms, which require a contamination-free environment with strict limits on airborne particles. To meet this requirement, ACS engineers sourced materials and designed functional elements that met both Class 5 cleanroom standards and could withstand the conditions of liquid nitrogen cold soaking.
For example, the company intended for the system to use electrical actuators. However, ACS engineers determined during the design phase that components such as ball bearings and lubricants would not meet the cleanliness and material compatibility requirements of a Class 5 cleanroom. They instead designed a system of pneumatic actuation for the system. This design ensures reliable operation even after repeated altitude testing cycles.
Although actuation was pneumatic, the remaining electrical components and wiring needed careful packaging to minimize exposed surfaces and wiring, reducing the risk of contamination. ACS electrical engineers and fabricators created compact routing and shielding solutions, as well as enclosures that protect sensitive electronics while still allowing operators easy access during maintenance.
ACS delivered a flexible, efficient dewar system that met the aerospace manufacturer’s performance, environmental, and cleanroom requirements for their component altitude testing.
The dual-basket configuration and automated liquid nitrogen management reduce operating costs by optimizing consumption based on actual component mass and soak testing needs. Automation also boosts throughput and eliminates the manual inefficiencies of the previous system. Engineered material choices, pneumatic actuation, and a compact electrical design ensure safe, reliable operation in a Class 5 cleanroom while remaining easy to service.
The project’s success has led to a second confirmed project, reflecting the manufacturer’s satisfaction with both the system and the engineering partnership behind it.