29th June 2026 | NDE Test Rig Innovation

NOVEL NDE TEST RIG DELIVERS MULTIPLE BENEFITS FOR SAFRAN

 

Coventry-based NDE Clarke Pitchline has developed a novel multi-purpose electro-pneumatic test rig for the highly accurate end-of-line testing of critical control assemblies and valves for fighter and trainer jets.

 

Developed initially in response to a specific request from Safran, the fully automated test rig integrates multiple test processes into a single operation, and can deliver to ±0.25% accuracy for both pressure and flow measurement.

 

Fully portable to enable use at numerous locations within Safran’s sites to optimise workflow, the new rig requires only standard electrical power and a standard compressed air supply, and is equally suited to both factory environments and on-apron ground support test roles.

 

It has halved the footprint of the test area, and has cut the time to test a single unit by more than 75 per cent, with individual test cycles previously lasting 40 minutes now completed in as little as nine minutes. The new rig has also deskilled the process, meaning more members of the team can use it, optimising output and efficiency.

 

Testing was previously undertaken on multiple 'legacy' test fixtures, dating as far back as the early 1960s, and required a skilled and experienced operator to oversee the test process. The previous, larger testing module was limited in where it could be used due to the location of the source high-pressure air supply outside the main factory footprint.

 

Both the controls and data acquisition (DAQ) functionality for the new rig were developed completely in-house by NDE’s dedicated engineering team at its Coventry headquarters.

 

 

Some of the test schedules involve high air pressure 'proof pressure' testing, so NDE developed a fully integrated and robust safety system with appropriate SIL rated hardware and controls logic. The existing equipment in service relied on ‘grandfather rights’ and a very limited safety inspection scheme.

 

This represents a major upgrade on the legacy test equipment which required detailed operator understanding of the risk control processes.

 

Traceability has improved too, with the new system automatically recording results for audit purposes.

 

The system has minimised the risk of foreign object and debris (FOD) ingress due to its novel design incorporating tightly fitting components.

 

Chris Edgington, Director at NDE Clarke Pitchline, explained: “This project for Safran clearly demonstrates our unique pedigree and prowess in meeting the exacting testing needs of the aerospace sector.

 

“Bespoke to a series of current and legacy aircraft control valves which the customer wants to test, the new rig has drastically improved test reliability uptime compared with a previous manual rig which was more challenging to calibrate and prone to human error.

 

“Meanwhile, intelligent packaging and pneumatic and electrical process control have allowed multiple test schedules under one system, which can be supported and amended for future test schedule updates.”