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SPECIAL TEST EQUIPMENT

Every test program is unique and often requires custom designed special equipment. Whether you need a small instrument or a larger piece of testing equipment, we can rapidly design and manufacture a variety of equipment in-house. From advanced wind tunnel models and artificial ice shapes to trailing cone systems and electrical load banks, AeroTEC’s rapid in-house design and manufacturing capabilities allow us to avoid delays and additional outsourcing costs.

All of our products can be designed to meet the specific needs of your aircraft and test campaign. Interested in a product you don’t see below? Contact us – chances are we can design and build one for you.

SPECIAL TEST EQUIPMENT

WIND TUNNEL MODELS

WIND TUNNEL MODELS

Custom Wind Tunnel Models for design & development of clean-sheet aircraft or modifications.

WIND TUNNEL MODEL DESIGN & BUILD

Low speed, Transonic and Supersonic Models
Full Stress Analysis (As Needed)
Powered Models (Controls or Thrust)
Instrumentation (Pressure taps, Accelerometers, Strain, Lift, Drag, Forces for lifting surfaces)
Designed for high test efficiency

WIND TUNNEL TEST SUPPORT

Wind Tunnel Facility Coordination
Test Plans
Test Conduct
Data Analysis

WIND TUNNEL MODEL FABRICATION

Models designed in-house for rapid response
Typical model production times are 2-3 months
Optional Powered control surfaces

WIND TUNNEL MODEL INSTRUMENTATION

Installation & measurements
Power system installation
Data analysis

LEARN MORE

ELECTRICAL LOAD BANK

Electrical Load Bank (ELB) system allows for validation of the aircraft power generation equipment by providing an electrical sink for excess power.

400L tanks capable to be filled with ice-water mix
Customizable for different airplane applications
Digital Control and indication can be implemented per special request

WATER BALLAST CONTROL SYSTEM (WTCS)

WATER BALLAST CONTROL SYSTEM (WTCS)

Water Ballast Transfer System for in-flight changes of center of gravity.

Allows transfer of CG during flight from control system
Independent tank pairs retain water
Scalable system for different size aircraft
Control and indication can be implemented into existing test software
Tanks are mounted on seat tracks in custom cradles; does not require airframe
modification
System can utilize 3Ph 115VAC or 28VDC power
Integrated backup battery capable to transfer full
volume at least two times
Protection for zero or negative g maneuvers to mitigate spills

FLUTTER EXCITATION VANE (FEV) SYSTEM

FLUTTER EXCITATION VANE (FEV) SYSTEM

Rotary Vane Flutter Excitation System (FES) designed to provide controllable force inputs for flutter excitation up to 70Hz across a wide speed range.

0 to 70 Hz force frequency output
±59 lb at 350 KEAS, medium sized vane
Operates on 28V DC Power, 30A peak current
High and Low force selection
1-5 vane system can be run simultaneously
Scalable system for larger or smaller force outputs depending on size of aircraft
Flutter exciter system for subsonic or supersonic airplane application
Digital control system with built in test profiles or custom discrete frequency test points
Touch Screen
System can be shutdown manually by pilot or via software control
ARINC Interface

TRAILING CONES & REELING MACHINE

TRAILING CONES & REELING MACHINE

Trailing cone and reeling system designed for flight test applications for accurate measurement of static pressure.

HOSE

Hose length: 50-150m
High Speed and low speed trailing cone assemblies developed for low or high-speed testing

REELING MACHINE

Scalable system for any size aircraft from FAA Part 23 to Part 25 (Bizjet to B747)
Manual retraction capability
Direct data output for pressure and hose length to DAS
Remote control
Configurable hose length
Power Requirements: 3PH/115VAC/400Hz or 28VDC, 500 Watt
Typical Weight (737 class system): ~400 lb
Data Output Format: RS-485 or analog

CUSTOM SENSOR & MOUNTING BETA VANE

custom-sensor-and-moutning-beta-vane-2023-04

CUSTOM SENSOR AND MOUNTING BETA VANE

Alpha & Beta Vanes evaluate the angle of attack (AOA). This can indicate a critical flight phase that may result in a stall or spin.

Customizable stainless steel and aluminum construction
Precision analog position sensor with raw output
- 5kΩ resistance
- 340° active electrical angle
- 7Ω per degree resolution
- 0.1% output smoothness
Mountable in either beta or alpha configurations

APU TEST RIG

APU TEST RIG

An Auxiliary Power Unit (APU) Test Rig evaluates the performance of a design’s fuel, power, performance and additional operating factors to confirm the compliance according to regulations.

APU Fire Detection and Suppression System Testing
Flow Measurement Validation Test Setup
Cooling Air Flow Supply Validation
Test Planning, Setup and Execution

ARTIFICIAL ICE SHAPES

ARTIFICIAL ICE SHAPES

Our team can design and build artificial ice shapes for ice accretion flight testing using NASA’s LEWICE Ice accretion software, Star-CCM+ and in-house manufacturing capabilities.

TOOL DEVELOPMENT

Ice shape tooling as needed – Leading edges and nose shapes
Tooling or parts can be built off existing parts or 3D models

SHAPES

Fully built shapes for all phases of icing certification
Fully removable and reusable
FAA or EASA approval of end-to-end process

HOT FUEL TEST RIG

HOT FUEL TEST RIG

Key Features

Hot Fuel Test Rig for certification testing of hot fuel effects on aircraft and systems. System is intrinsically safe with no fuel touching heating system.

Nominally designed to heat 6,500 lb of fuel from 70˚ F to 150˚ F in less than 4 hours with a 200,000 BTU per hour water heater set at 180˚ F
Installs in fuel truck tank, no permanent fuel truck modifications required
Heating system can be gas or electric, no direct contact with fuel
In tank thermocouples provide direct measurement of fuel temperature
2kW 220VAC 1PH for pump and water heater control electronics
Intrinsically safe design
Flow rate up to 1kg/s
ΔT up to 22ºC
Max fuel temperature 65ºC ± 5ºC

TAILSKID

Custom designed tailskids for re-usable flight test applications.

Custom designed tail skid hardware for takeoff and landing testing
Crushable cylinder used for energy absorption, can be replaced each test in 30 minutes or less
Cylinder designed to prevent damage to fuselage
Replaceable wear pads designed for significant runway contact during over rotation event

Can we designed for variable energy absorption characteristics.

FLIGHT TEST DATA SYSTEM RACK & WORKSTATION

ste-flighttestdatasystemrackandworkstation

FLIGHT TEST DATA SYSTEM RACK & WORKSTATION

The Data System Rack & Workstation houses the monitoring system during Flight Test. The rack houses the instrumentation and data acquisition system which records data for subsequent analysis.

DATA SYSTEM RACK

Standard 19” racks with single and dual configuration
Customizable height and length, per customer specs
Light-weight aluminum structure
Up to 500lb equipment load per rack

WORKSTATION

Single, dual, or triple seat workstation
Customizable monitor arrangement
Customizable central console with DZUS interface
Workstation installation is customizable for individual application

FLIGHT TEST VIDEO SYSTEM

Heated flight test video system for all subsonic and transonic flight regimes including natural icing.

Internally heated with external hoods for ice/fog free visibility
SDI output and interchangeable lenses
Adjustable mount for changeable field of view
Fixed base camera mounts available
Rated for transonic flight
Power Requirements:
- 300W (DC/AC) per camera maximum power draw
- Controller 115VAC @ 5 amps

LANDING GEAR TEST RIGS

LANDING GEAR TEST RIGS

Landing gear testing and test rig development for main and nose landing gears on FAA part 23 or part 25 aircraft.

Aircraft Gross Weights of 1,000 lbs – 40,000 lbs or above as needed
Data Acquisition Support (Accelerometers, Load Measurement, Strain Gauges, Thermography, High Speed Cameras (240FPS), Deflections, Strut and Tire Pressures – Typical Measurements)
Static Ground Loads Testing
Dynamic Landing Loads Testing
Company POC Testing
Certification Testing
STC Support for Increased Gross Weights
In-house design and manufacturing of all mounting hardware
Wheel spin-up loads as needed

Design and development of landing gear test rigs for part 23 and 25 aircraft.

TOWBAR ADAPTER

Custom towbar adapters manufactured for specific special mission aircraft.

Custom towbar adapter
Fused pins for tension/compression and torsion
Customizable to specific airplane requirements

CONTROL SURFACE DEFLECTION GAUGE

ATEC-15017-1
Key Features
- Easy and non-destructive mounting to non-planer surfaces
- Mounting provided by vacuum operated rubber suction cups
- 17 bit absolute optical encoder
- ±.03 degree angular accuracy
- Includes both digital readout and supports real time RS-232 and RS-485 serial output
- High precision machined aluminum construction
- Can be used for an absolute or relative angular measurement
- Up to ±90° measurement range (dependent on attachment)
Encoder Specifications
- Dynapar Series AI25 SSI
- Resolution: 17 Bit
- Linearity: ± ½ LSB
- Absolute Accuracy: ± 0.01° mechanical
- Repeatability: ± 0.002° mechanical
- Code Format: Grey
Readout and Serial Interface
- Motrona IX 348
- Display: 6 Decade LED
- Output: Configurable to RS-232 or RS-485
External Requirements
- Power: 115VAC or 230VAC
- Compressed Air: 4.8 CFM at 80 PSI

BOEING 737-700/800/900 SPLIT SCIMITAR WINGLET LIGHTING TEST BOX

ATEC-13088
Key Features
- Works on 90 – 264 VAC, 47 – 63 Hz
- Provides necessary output voltages for Position Lights and Anti-Collision Lights

SOLUTIONS MADE FOR YOUR PROGRAM

SINCE 2003

ACCELERATING THE EVOLUTION OF AEROSPACE

AeroTEC develops, tests and certifies new aerospace products, leveraging our integrated assets to help innovators everywhere bring their products to market quickly and efficiently.

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AEROTEC HEADQUARTERS

5601 6TH AVE S #410, SEATTLE, WA 98108
206.763.6087