Success Story: Test bench for hydraulic rotary actuators up to 65,000 Nm

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Test bench for hydraulic rotary actuators up to 65,000 Nm: end-of-line testing with traceability and automatic reporting

The test bench for hydraulic rotary actuators is a strategic tool for quality control, traceability and performance certification.

The system presented here is the result of a collaboration between Mekoil Oleodinamica and Duplomatic, and has been designed for end-of-line integration at a leading manufacturer of semi-rotary actuators, with the goal of validating each component under real operating conditions.

The bench ensures repeatability of tests, stability of setpoints and automatic generation of the test report associated with each individual actuator.

The system handles torques up to 65,000 Nm and pressures up to 350 bar, with angular precision below 0.1°, providing an advanced infrastructure to structure a production process aligned with Industry 4.0 principles.

Continue reading to discover the system architecture, control logic and design choices.

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What is a hydraulic semi-rotary actuator?

A hydraulic semi-rotary actuator is a device that converts hydraulic energy (oil pressure and flow rate) into rotary motion over a limited angle. Unlike a hydraulic motor, it does not operate in continuous rotation: it performs a movement within a defined range (for example 90°, 180°, 270° and, in some applications, up to 360°).

It is the ideal solution when it is necessary to:

• apply high torque
• ensure precise angle control
• guarantee repeatability within the cycle
• maintain stability under load

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Test range and nominal performance

The test bench is designed for high-torque and high-pressure testing, with integrated cycle control and data acquisition.

The nominal performance specifications are:

• maximum torque: 65,000 Nm
• operating pressure: 350 bar
• rotation range: up to 360°
• rotation speed under load: 2 rpm
• angular precision: < 0.1°
• operational noise level: < 80 dB

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Cycle control: PC/PLC and stable flow and pressure management

The test bench operates in fully automatic mode through PC and PLC, with dedicated software for sequence management and acquisition of test parameters.

A manual mode via operator interface is also available, useful for setup, maintenance and verification activities.

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Setpoint stability

The management of flow rate and supply pressure to the component under test is achieved through Daikin Industries drives integrated into the bench architecture jointly developed by Mekoil and Duplomatic, with the objective of maintaining stable setpoints throughout the entire cycle.

This makes it possible to:

• maintain constant setpoints
• simulate real operating cycles
• manage variable loads
• reproduce controlled speed variations

The result is a stable and comparable test process over time.

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Angular precision and repeatability

One of the key requirements when testing semi-rotary actuators is the accuracy of angular control and positioning repeatability.

The system guarantees angular control with precision below one tenth of a degree (< 0.1°), helping ensure that testing results are comparable from one component to another and consistent over time.

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Fluid management and process reliability

Oil conditions directly influence test repeatability and actuator behavior stability. For this reason, the test bench integrates dedicated functions for fluid quality and system management:

• monitoring and recording the oil contamination level among the test parameters
• offline filtration circuit at 5 microns
• electrical and visual indicators of filter clogging
• oil temperature control to guarantee stable thermal conditions
• automatic draining cycle of the component at the end of the test

Operational noise is kept below 80 dB, facilitating the integration of the bench within a production environment.

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Energy efficiency with Daikin–Mekoil servo pump

The bench adopts a servo pump developed through the collaboration between Daikin and Mekoil.

This solution enables:

• dynamic power modulation
• reduction of energy consumption
• optimization during variable load phases
• higher efficiency compared with traditional systems

Energy efficiency thus becomes an integral part of the project.

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Automatic reporting: traceability and test certification

At the end of each test, the system automatically generates a test report, a key element for structured quality management.

The reporting system allows:

• associating parameters and results with each individual actuator
• storing and comparing tests over time
• supporting production traceability and internal verification processes

Complete traceability transforms testing into a strategic quality management tool.

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What are the advantages of end-of-line integration?

Integrating a hydraulic rotary actuator test bench at the end of the production line means:

• validating every component before shipment
• reducing non-conformities and returns
• increasing customer confidence
• standardizing the production process

Thanks to PC/PLC control, stable flow and pressure management, advanced fluid handling and automatic reporting, each actuator is validated under real operating conditions with traceable parameters and documented performance.

In a market increasingly oriented toward documented quality and digitalization, investing in an advanced test bench means investing in industrial competitiveness.

Testing solutions and validation systems are part of the activities of the Systems Business Unit of Duplomatic, specialized in the development of test benches and integrated systems for industrial and hydraulic applications.

 

WATCH THE FULL VIDEO!

CONTACT US: sales.exp@duplomatic.com

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