A leading aerospace component manufacturer faced a critical need to significantly increase their End Of Line (EOL) testing capacity for a crucial aerospace component at their existing facility. The client required a comprehensive turnkey solution that could be seamlessly integrated into their current operational environment with minimal to no onsite construction disruption. The primary challenge was to deliver a high-performance aerospace testing solution that could not only meet their expanding production volumes but also adhere to stringent aerospace industry standards for safety, noise mitigation, and data integrity, all within the constraints of an active facility, impacting their aerospace end of line test capabilities.
ACS delivered a complete turnkey solution by designing and building a fully integrated, self-contained test cell enclosure for the aerospace component’s production. This innovative approach ensured rapid deployment with minimal onsite impact, specifically for aerospace end of line test processes. The enclosure’s takt time was precisely correlated to the client’s production build volumes, optimizing throughput for aerospace testing. Constructed with a full structural frame, the test cell featured advanced sound-mitigating and fire-rated walls, along with a robust structural floor designed for spill containment. Two double-leaf sound doors ensured acoustic isolation, while a scavenge exhaust system was seamlessly integrated into the frame for safety and environmental control.
The aerospace component test cell is equipped with a mechanical bulkhead for all process piping and a single source of electrical power, providing complete distribution for motor loads, container conditioning, lighting, and general-purpose receptacles. The test cell is self-contained, portable within the facility, and ties to existing facility systems, enhancing their aerospace end of line test capabilities. The test enclosure includes a 24/7 PLC-based Safety Instrumented System (SIS) with gas detection, temperature and ventilation monitoring and control, and an NI™ LabVIEW data acquisition platform, essential for comprehensive aerospace testing.
ACS successfully provided the client with an advanced, fully integrated aerospace component test cell that significantly increased their aerospace end of line test capacity and streamlined their production process. The self-contained and portable design of the test cell enclosure minimized disruption during installation, allowing the client to maintain continuous operations. The robust construction, incorporating sound-mitigating and fire-rated features, ensured a safe and controlled aerospace testing environment compliant with aerospace standards. The integrated safety systems and high-resolution data acquisition capabilities provided the client with reliable performance validation and critical insights into their aerospace components, contributing to enhanced product quality and faster certification processes. This project not only met the immediate demands for increased testing capacity but also provided a flexible, long-term solution that can be easily adapted or relocated within the facility to support future production needs for aerospace end of line test.