An Innovative Solution To Compliance Testing At Moog Controls

Moog specialises in the design and development of combined hydraulic and electrical products used in a range of critically demanding control system applications in the aerospace, power generation, motorsport and other industry sectors.

Recently, as part of the introduction of an advanced technology electrically controlled fuel control manifold product utilised in aircraft, Moog upgraded its production and quality control processes with the introduction of a new integrated test station developed by Clare Instruments.

The three part Clare system incorporates an advanced Hal Combi tester linked to a PLC control interface and safety test enclosure. This configuration is designed to enable each product to have multiple circuits tested individually to ensure full compliance with rigorous technical and quality standards. Any circuit that fails is uniquely indicated for rectification.

The semi-automatic system enables a range of key electrical safety tests to be carried out automatically on each manifold system. Hydraulic and other functional tests are carried out as part of the product build process and the electrical safety test station forms one of the final stages of manufacturing to confirm product compliance, quality and reliability.

The customised Clare test station features special safety interlocks that reduce operator involvement to the simple loading and un-loading of products into the enclosure. When the enclosure door is closed the Hal Combi automatically sequences through the required earth bond (continuity), flash/hipot/dielectric withstand and insulation resistance tests on individual circuits within the product.

Test connections are made by low-pressure insertion industrial test probes that are colour coded to match the product cabling. The purpose designed test nest jig means the product can only be inserted in one position to eliminate loading errors and spring loaded terminals are used to enable fast connection of product wire connections.

Given the complexity of the Moog products under test and the demanding test specifications involved, the test duration for each product lasts around 40 minutes. The test control unit is equipped with a series of status lamps for each of the tests carried out so that in the event of failure the operator can see which test has failed, allowing remedial action to be taken.

A successful test is indicated by illuminated test pass and test complete lamps.

The test station is linked to the internal Moog data control network enabling all relevant data to be captured for production management, quality assurance and statistical analysis purposes.

With the verification of performance quality and safe operation of electrical products regarded as crucial, integrated production line safety testing has become an essential part of the Moog Controls manufacturing and compliance process.