Airbus pressure testing unit
August 2003
Pressure Measurement & Control
Asset Management
Transport (Industry)
A Samsomatic testing unit is used for quality assurance tests during the final assembly of the Airbus A321. It is designed for testing the pressure resistance and air-tightness of the aeroplane's cabin. Tests are conducted before the cabin is furnished.
For the period of testing, it must be guaranteed that the unit can be pushed to the aeroplane, because this is moved from one assembly station to the other. The testing unit consists of two movable wagons which comprise all necessary instrumentation and control equipment, such as the control cabinet, the control valves, and the required accessories.
The pressure in the cabin must be increased according to an arbitrary time-dependent setpoint curve. It must be increased in several steps and at different rates, until it has assumed the maximum setpoint value. Then, the pressure is reduced, again in several steps and at different rates, to the air-tightness testing pressure. Once having completed this air-tightness test, the pressure has to be lowered to 0. After each program step, the program is interrupted, permitting the inspector to visually check the aeroplane. Afterwards, the next program step is started manually.
To protect the (very expensive) plane cabin against overpressure or excessive pressure rises or drops, the testing unit offers several safety precautions:
* Control loops are checked and monitored for system deviations and cable breakage (including alarm annunciation and control process interruption).
* Pressure monitors cause the air filling valve to close and the drain valve to open as soon as the pressure has reached a maximum limit.
* Mechanical safety valves.
* Electronic and mechanical travel limitation in order to provide safe limitation of pressure rises and drops.
* Failure-action of control valves in case of air or power failure.
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