Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENT RULES, 2003

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

Title of the invention:
A TEST RIG FOR TESTING HYDRAULIC POWER PACK AND METHOD OF TESTING THEREOF

Applicant:
GOA SHIPYARD LIMITED
(A Govt. of India Undertaking-Ministry of Defence)
Having address as:
GOA SHIPYARD LIMITED
Vasco-Da-Gama, GOA - 403802, India

The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD OF THE INVENTION

[001] The present invention relates to a test rig for testing Hydraulic Power Pack (HPP) and method of testing thereof. More particularly, present invention relates to a test rig for testing Hydraulic Power Pack of a controllable pitch propulsion system in ships.

BACKGROUND OF THE INVENTION
[002] In ships, Controllable Pitch Propellers (CPP) are used for higher propulsion efficiency by optimizing and improving maneuverability. CPP comprises of a hub with separate propeller blades mounted on it. A hydraulic mechanism is provided to rotate the blades simultaneously about their respective axes with respect to the hub to change the pitch angle of the propeller. This pitch angle is varied to change the speed of the ship without altering the rotational speed of the propeller. Moreover, the ship’s motion can be reversed from forward direction to astern direction or vice versa, by inverting propeller pitch. CPP enables this reversing motion of the ship to happen very smoothly and without any dead time, thus improves maneuverability.
[003] A Hydraulic Power Pack (HPP) is used to supply pressurized oil to the hydraulic mechanism of the CPP to change the propeller pitch angle. As shown in Figure 1, the HPP (10) comprises of an oil reservoir (not shown in figure), a drive motor (11) and a hydraulic pump. The drive motor (11) is connected to the hydraulic pump and drives the hydraulic pump to supply the oil from the reservoir to a manifold block (12). The manifold block (12) comprises of plurality of solenoid valves, pressure relief valve and proportional valve to distribute the pressurized oil to two hoses (13 & 14) connected to the manifold block (12). In actual use, these hoses (13 & 14) are connected to propeller hub for supplying oil to the hydraulic mechanism for changing the propeller blade pitch.
[004] In forward motion configuration of CPP, the manifold block (12) supplies oil to the first hose (13) and then to the hydraulic mechanism of CPP. The oil flows back from the hydraulic mechanism to the manifold block (12) through second hose (14). Whereas, in reverse/astern motion configuration of the CPP, the oil is supplied to the hydraulic mechanism through second hose (14) and flows back to the manifold block (12) through the first hose (13).
[005] Prior to putting in use, HPP needs to be tested in factory by carrying out Factory Acceptance Test (FAT) for checking the functionality of the manifold block. Moreover, the pressure relief valve and pressure setting valves needs to be adjusted and tuned. Therefore, there is a need to develop a testing rig and a method of testing for performing FAT of the HPP.

OBJECTS OF THE INVENTION
[006] The object of the invention is to provide a test rig to carry out Factory Acceptance Test (FAT) of a Hydraulic Power Pack (HPP).
[007] Another object of the invention to provide a method of testing Hydraulic Power Pack (HPP) in factory.
[008] Yet another object of the invention is to provide a test rig for checking functionality of a manifold block of a Hydraulic Power Pack (HPP).
[009] Yet another object of the invention is to provide a test rig for recording test parameters of HPP like oil flow rate, oil pressure, oil temperature and current drawn by the drive motor of the HPP.

SUMMARY OF THE INVENTION
[0010] Before the present system is described, it is to be understood that this application is not limited to the particular machine or an apparatus, and methodologies described, as there can be multiple possible embodiments that are not expressly illustrated in the present disclosure. It is also to be understood that the terminologies used in the description is for the purpose of describing the particular version or embodiment only and is not intended to limit the scope of the present application. This summary is provided to introduce aspects related to a test rig for testing hydraulic power pack and method of testing thereof, and the aspects are further elaborated below in the detailed application description. This summary is not intended to identify essential features of the proposed subject matter nor is it intended for use in determining or limiting the scope of the proposed subject matter.
[0011] A test rig and a method for testing a Hydraulic Power Pack (HPP) are provided in the present invention. The test rig comprises a first pipe including a first connection opening for connecting a first hose of the HPP and a second pipe including a second connection opening for connecting a second hose of the HPP. The first pipe comprises of a first non-return valve (NRV) provided on one side of the first connection opening and a third NRV provided on opposite side of the first connection opening. The second pipe comprises of a second NRV provided on one side of the second connection opening and a fourth NRV provided on opposite side of the second connection opening. All the NRVs allow the oil flow in same direction (i.e., upwards). The first pipe and the second pipe are connected in a parallel configuration. A third pipe including a flow meter and a throttle valve is connected in series to the first pipe and the second pipe. The flow meter measures oil flow rate, oil pressure and oil temperature. The throttle valve changes the oil pressure by varying degrees of opening. In a forward motion configuration of the HPP, pressurized oil is supplied to the first hose and oil flows back through the second hose. In a reverse/astern motion configuration of the HPP, pressurized oil is supplied to the second hose and oil flows back through the first hose.
[0012] The HPP is run in forward motion configuration and the throttle valve is gradually closed to generate a first predetermined oil pressure. Then the oil pressure is increased to a second predetermine pressure by operating a pressure relief valve provided on HPP and rigidity of HPP for leakages is checked. Further, test parameters are recorded by completely opening the throttle valve. Further, the throttle valve is gradually closed and test parameters are recorded at a plurality of predetermined pressure values. The test parameters include oil flow rate, oil pressure, oil temperature and current drawn by drive motor of the HPP. The HPP is switched to reverse/astern motion configuration and the test procedure is repeated.

STATEMENT OF INVENTION
[0013] The present subject matter discloses a test rig for testing Hydraulic Power Pack (HPP). The test rig comprises of plurality of pipes for connecting hoses of the HPP, plurality of non-return valves (NRVs) configured to direct the oil received from the HPP in a predetermined direction for testing the HPP in forward or reverse/astern motion configuration, at least one flowmeter configured to be mounted in the test rig for measuring oil flow rate, oil pressure and oil temperature, and at least one throttle valve configured to be mounted in the test rig for varying the oil pressure. The plurality of pipes comprises of a first pipe configured to be connected to a second pipe in parallel configuration and a third pipe configured to be connected in series to the first pipe and second pipe. The first pipe comprises of a first connection opening for connecting a first hose of the HPP, a first non-return valve (NRV) provided on one side of the first connection opening and a third NRV provided on another side of the first connection opening. The second pipe comprises a second connection for connecting a second hose of the HPP, a second non-return valve (NRV) provided on one side of the second connection opening and a fourth NRV provided on another side of the second connection opening. The third pipe is configured with the flow meter and the throttle valve provided downstream of the flow meter. In forward motion configuration, the HPP is configured to supply pressurized oil to the first connection opening through the first hose to flow to the first NRV, the flow meter, the throttle valve, the fourth NRV, the second connection opening, through the second hose to the HPP, sequentially. In reverse/astern motion configuration, the HPP is configured to supply pressurized oil to the second hose to flow to the second NRV, the flow meter, the throttle valve, the third NRV, the first connection opening, through the first hose to the HPP, sequentially.
[0014] The present invention further discloses a method of testing a Hydraulic Power Pack (HPP) on a test rig. The method comprises steps of;
a. connecting a first hose of the HPP to a first connection opening in a first pipe of the test rig;
b. connecting a second hose of the HPP to a second connection opening on a second pipe of the test rig;
c. turning on the HPP and actuating a manifold block to supply the pressurized oil to the test rig for testing the HPP in a preselected configuration (forward or reverse/astern motion);
d. closing a throttle valve provided in a third pipe of the test rig gradually, to generate a first predetermined pressure in the HPP;
e. actuating a pressure relief valve of the HPP to increase oil pressure to a second predetermined pressure and checking rigidity of the HPP for leakages;
f. opening the throttle valve completely and recording test parameters; and
g. closing the throttle valve gradually and recording the test parameters at plurality of predetermined pressure values.
In the forward motion configuration of the HPP, pressurized oil is supplied to the first connection opening and oil flows back to HPP through the second connection opening. In the reverse/astern motion configuration of the HPP, pressurized oil is supplied to the second connection opening and oil flows back to HPP through the first connection opening. The test parameters include oil flow rate, oil pressure, oil temperature and current drawn by a drive motor of the HPP.

BRIEF DESCRIPTION OF DRAWINGS
[0015] The foregoing summary, as well as the following detailed description of embodiment, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating of the present subject matter, an example of construction of the present subject matter is provided as figures; however, the disclosure is not limited to the specific method and apparatus disclosed in the document and the drawings.
[0016] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawing to refer like features and components.
[0017] Figure 1 illustrates a Hydraulic Power Pack (10);
[0018] Figure 2 illustrates a hydraulic circuit diagram of the test rig, in accordance to the present disclosure;
[0019] Figure 3 illustrates a block diagram of the test rig, in accordance to the present disclosure;
[0020] Figure 4 illustrates a hydraulic flow circuit of the test rig in forward motion configuration of the HPP, in accordance to the present disclosure;
[0021] Figure 5 illustrates a hydraulic flow circuit of the test rig in reverse/astern motion configuration of the HPP, in accordance to the present disclosure; and
[0022] Figure 6 illustrates a flowchart of a method of testing a Hydraulic Power Pack on the test rig, in accordance to the present disclosure.
[0023] Figures depict various embodiments of the present disclosure for purpose of illustration only. Only skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION OF THE INVENTION
[0024] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words “comprising”, “having”, and “including,” and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. Although any systems similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the exemplary, test rig for testing hydraulic power pack and method of testing thereof are now described. The disclosed embodiments are merely exemplary of the disclosure, which may be embodied in various forms.
[0025] Various modification to the embodiment will be readily apparent to those skilled in the art and the generic principles herein may be applied to another embodiment. However, one of ordinary skill in the art will readily recognize that the present disclosure is not intended to be limited to the embodiments illustrated but is to be accorded the widest scope consistent with the principles and features described herein.
[0026] Now referring to Figures 1, 2 and 3, the disclosure herein provides a test rig for testing a Hydraulic Power Pack (HPP) (10), as shown in Figure 1. Figure 2 illustrates a hydraulic circuit diagram of the test rig (20) and Figure 3 illustrates a block diagram of the test rig (20). The test rig (20) comprises of a first pipe (31) including a first connection opening (25) for the connection of first hose (13) of the HPP (10) and a second pipe (32) including a second connection (26) for the connection of second hose (13) of the HPP (10) (refer Figure 1). The first pipe (31) comprises of a first non-return valve (NRV) (21) and a third non-return valve (NRV) (23) provided on opposite sides of the first connection opening (25). The second pipe (32) comprises of a second non-return valve (NRV) (22) and a fourth non-return valve (NRV) (24) provided on opposite sides of the second connection opening (26). The first pipe (31) is connected to the second pipe (32) in a parallel configuration and a third pipe (33) is connected in series to the first pipe (31) and the second pipe (32). The third pipe (33) comprises of a flow meter (27) and a throttle valve (28) provided downstream of the flow meter (27). The flow meter measures oil flow rate, oil pressure & oil temperature. The throttle valve (28) varies the oil flow through it and oil pressure upstream the throttle valve by changing the degrees of opening of the throttle valve (28). All the NRVs (21, 22, 23 and 24) are configured to allow the flow of oil in same direction (i.e., in vertically upward direction).
[0027] Figure 4 illustrates the fluid flow diagram in forward motion configuration of the HPP (10). When the hoses (13 and 14) of the HPP (10) are connected to the respective connection openings (25 and 26) of the test rig (20) and the HPP (10) is operated in a forward motion configuration, the pressurized oil from HPP enters the first pipe (31) through the first connection opening (25). As the third NRV (23) does not allow the flow in downward direction, and the oil flows through the first NRV (21) to the flow meter (27). The pressurized oil then flows through the throttle valve (28) and through the fourth NRV (24) to the second connection opening (26) of the second pipe (32). Then the oil is supplied back to the HPP (20) through the second hose (14). As the oil pressure above the third NRV (23) is more that of the oil coming from the throttle valve (28), the oil doesn’t flow upwards through the third NRV (23).
[0028] Figure 5 illustrates the fluid flow diagram in reverse/astern motion configuration of the HPP (10). When the HPP (10) is operated in the reverse/astern motion configuration, the pressurized oil from HPP enters the second pipe (32) through the second connection opening (26). As the fourth NRV (24) does not allow the flow in downward direction, the oil flows through the second NRV (22) to the flow meter (27). The pressurized oil then flows through the throttle valve (28) and through the third NRV (23) to the first connection opening (25) of the first pipe (31). Then the oil is supplied back to the HPP (20) through the first hose (13). As the oil pressure above the fourth NRV (24) is more that of the oil coming from the throttle valve (28), the oil doesn’t flow upwards through the fourth NRV (24).
[0029] In another embodiment, in forward and/or reverse/astern motion configuration of the HPP (10), the throttle valve (28) is gradually closed to generate a first predefined pressure (e.g., 135 bar) in the HPP (10). Then, the pressure is further increased to a second predefined pressure (e.g., 204 bar) and kept for a predetermined time to check rigidity of the HPP (10) for leakages.
[0030] In another embodiment, the throttle valve (28) is completely opened (i.e., 100% degrees of opening) and the parameters are recorded such as oil pressure, oil temperature, flow rate and current drawn by the drive motor (11) of the HPP (10).
[0031] In another embodiment, the throttle valve (28) is gradually closed and oil temperature, flow rate and current drawn by the motor are measured.
[0032] Figure 6 shows a flowchart of the method (600) of testing the HPP (10) on the test rig (20). At 601, first hose (13) of the HPP (10) is connected to a first connection opening (25) of the test rig (20) and the second hose (14) of the HPP (10) are connected to the second connection opening (26) of the test rig (20). At 602, the HPP (10) is turned on and the manifold block (12) is actuated in forward motion configuration to supply the pressurized oil to the first hose (13) and oil returns back to the HPP (10) through the second hose (14) after flowing through first NRV (21), flow meter (27), throttle valve (28) and fourth NRV (24). At 603, the throttle valve (28) is gradually closed to achieve a first predetermined pressure in the HPP (10). At 604, a pressure relief valve is operated on the HPP (10) to achieve a second predetermined pressure and kept at that pressure for a predetermined time to check rigidity of the HPP (10) for leakages. At 605, the throttle valve (28) is completely opened (100% opening) and test parameters are recorded, wherein the test parameters include oil flow rate, oil pressure, oil temperature measured by the flow meter (27) and current t drawn by the drive motor (11) measured on the HPP (10). At 606, the throttle valve is gradually closed and test parameters are recorded at plurality of predetermined oil pressure values. At 607, the manifold block (12) is actuated in reverse/astern motion configuration and the test process is repeated.
[0033] Accordingly, present invention discloses a test rig (20) for testing Hydraulic Power Pack (HPP) (10). The test rig (20) comprises of plurality of pipes (31, 32, 33) for connecting hoses (13, 14) of the HPP (10), plurality of non-return valves (NRVs) (21, 22, 23, 24) configured to direct the oil received from the HPP (10) in a predetermined direction for testing the HPP (10) in forward or reverse/astern motion configuration, at least one flowmeter (27) configured to be mounted in the test rig (20) for measuring oil flow rate, oil pressure and oil temperature, and at least one throttle valve (28) configured to be mounted in the test rig (20) for varying the oil pressure. The plurality of pipes comprises of a first pipe (31) configured to be connected to a second pipe (32) in parallel configuration and a third pipe (33) configured to be connected in series to the first pipe (31) and second pipe (32). The first pipe (31) comprises of a first connection opening (25) for connecting a first hose (13) of the HPP (10), a first non-return valve (NRV) (21) provided on one side of the first connection opening (25) and a third NRV (23) provided on another side of the first connection opening (25). The second pipe (32) comprises a second connection (26) for connecting a second hose (14) of the HPP (10), a second non-return valve (NRV) (22) provided on one side of the second connection opening (26) and a fourth NRV (24) provided on another side of the second connection opening (26). The third pipe (33) is configured with the flow meter (27) and the throttle valve (28) provided downstream of the flow meter (27). In forward motion configuration, the HPP (10) is configured to supply pressurized oil to the first connection opening (25) through the first hose (13) to flow to the first NRV (21), the flow meter (27), the throttle valve (28), the fourth NRV (24), the second connection opening (26), through the second hose (14) to the HPP (10), sequentially. In reverse/astern motion configuration, the HPP (10) is configured to supply pressurized oil to the second hose (14) to flow to the second NRV (22), the flow meter (27), the throttle valve (28), the third NRV (23), the first connection opening (25), through the first hose (13) to the HPP (10), sequentially.
[0034] The present invention further discloses a method of testing a Hydraulic Power Pack (HPP) (10) on a test rig (20). The method comprises steps of;
a. connecting a first hose (13) of the HPP (10) to a first connection opening (25) in a first pipe (31) of the test rig (20);
b. connecting a second hose (14) of the HPP (10) to a second connection opening (26) on a second pipe (32) of the test rig (20);
c. turning on the HPP (10) and actuating a manifold block (12) to supply the pressurized oil to the test rig (20) for testing the HPP (10) in a preselected configuration (forward or reverse/astern motion);
d. closing a throttle valve (28) provided in a third pipe (33) of the test rig (20) gradually, to generate a first predetermined pressure in the HPP (10);
e. actuating a pressure relief valve of the HPP (10) to increase oil pressure to a second predetermined pressure and checking rigidity of the HPP (10) for leakages;
f. opening the throttle valve (28) completely and recording test parameters; and
g. closing the throttle valve (28) gradually and recording the test parameters at plurality of predetermined pressure values.
In the forward motion configuration of the HPP (10), pressurized oil is supplied to the first connection opening (25) and oil flows back to HPP (10) through the second connection opening (26). In the reverse/astern motion configuration of the HPP (10), pressurized oil is supplied to the second connection opening (26) and oil flows back to HPP (10) through the first connection opening (25). The test parameters include oil flow rate, oil pressure, oil temperature and current drawn by a drive motor (11) of the HPP (10).
[0035] Exemplary embodiments discussed above may provide certain advantages. Though not required to practice aspects of the disclosure, these advantages may include the following:
[0036] Some embodiments of the present subject matter provide a test rig to carry out Factory Acceptance Test (FAT) of a Hydraulic Power Pack (HPP).
[0037] Some embodiments of the present subject matter provide a method of testing Hydraulic Power Pack (HPP) in factory.
[0038] Some embodiments of the present subject matter provide a test rig for checking functionality of a manifold block of a Hydraulic Power Pack (HPP).
[0039] Some embodiments of the present subject matter provide a test rig for recording test parameters of HPP like oil flow rate, oil pressure, oil temperature and current drawn by the drive motor of the HPP.
[0040] Although implementations for a test rig for testing hydraulic power pack and method of testing thereof, have been described in language specific to structural features and/or system, it is to be understood that the appended claims are not necessarily limited to the specific features described. Rather, the specific features are disclosed as examples of implementations.
[0041] Below is a list of elements with reference numerals which may be used for implementation of the present subject matter.
Reference Numerals Element name
10 Hydraulic Power Pack (HPP)
11 Drive motor
12 Manifold block
13 First hose
14 Second hose
20 Test rig
21 First non-return valve
22 Second non-return valve
23 Third non-return valve
24 Fourth non-return valve
25 First connection opening
26 Second connection opening
27 Flowmeter
28 Throttle valve
31 First pipe
32 Second pipe
33 Third pipe

, Claims:
1. A test rig (20) for testing Hydraulic Power Pack (HPP) (10) comprising:
plurality of pipes (31, 32, 33) for connecting hoses (13, 14) of the HPP (10);
plurality of non-return valves (NRVs) (21, 22, 23, 24) configured to direct the oil received from the HPP (10) in a predetermined direction for testing the HPP (10) in forward or reverse/astern motion configuration;
at least one flowmeter (27) configured to be mounted in the test rig (20) for measuring oil flow rate, oil pressure and oil temperature; and
at least one throttle valve (28) configured to be mounted in the test rig (20) for varying oil pressure.
2. The test rig (20) for testing Hydraulic Power Pack (HPP) (10) as claimed in claim 1, wherein the plurality of pipes comprises of a first pipe (31) configured to be connected to a second pipe (32) in parallel configuration and a third pipe (33) configured to be connected in series to the first pipe (31) and second pipe (32).
3. The test rig (20) for testing Hydraulic Power Pack (HPP) (10) as claimed in claim 1, wherein the first pipe (31) comprises of a first connection opening (25) for connecting a first hose (13) of the HPP (10), a first non-return valve (NRV) (21) provided on one side of the first connection opening (25) and a third NRV (23) provided on another side of the first connection opening (25).
4. The test rig (20) for testing Hydraulic Power Pack (HPP) (10) as claimed in claim 1, wherein the second pipe (32) comprises a second connection (26) for connecting a second hose (14) of the HPP (10), a second non-return valve (NRV) (22) provided on one side of the second connection opening (26) and a fourth NRV (24) provided on another side of the second connection opening (26).
5. The test rig (20) for testing Hydraulic Power Pack (HPP) (10) as claimed in claim 1, wherein the third pipe (33) is configured with the flow meter (27) and the throttle valve (28) provided downstream of the flow meter (27).
6. The test rig (20) for testing Hydraulic Power Pack (HPP) (10) as claimed in claim 1, wherein, in forward motion configuration, the HPP (10) is configured to supply pressurized oil to the first connection opening (25) through the first hose (13) to flow to the first NRV (21), the flow meter (27), the throttle valve (28), the fourth NRV (24), the second connection opening (26), through the second hose (14) to the HPP (10), sequentially.
7. The test rig (20) for testing Hydraulic Power Pack (HPP) (10) as claimed in claim 1, wherein, in reverse/astern motion configuration, the HPP (10) is configured to supply pressurized oil to the second hose (14) to flow to the second NRV (22), the flow meter (27), the throttle valve (28), the third NRV (23), the first connection opening (25), through the first hose (13) to the HPP (10), sequentially.
8. A method of testing a Hydraulic Power Pack (HPP) (10) on a test rig (20), comprises steps of:
connecting a first hose (13) of the HPP (10) to a first connection opening (25) in a first pipe (31) of the test rig (20);
connecting a second hose (14) of the HPP (10) to a second connection opening (26) on a second pipe (32) of the test rig (20);
turning on the HPP (10) and actuating a manifold block (12) to supply the pressurized oil to the test rig (20) for testing the HPP (10) in a preselected configuration (forward or reverse/astern motion);
closing a throttle valve (28) provided in a third pipe (33) of the test rig (20) gradually, to generate a first predetermined pressure in the HPP (10);
actuating a pressure relief valve of the HPP (10) to increase oil pressure to a second predetermined pressure and checking rigidity of the HPP (10) for leakages;
opening the throttle valve (28) completely and recording test parameters; and
closing the throttle valve (28) gradually and recording the test parameters at plurality of predetermined pressure values.
9. A method of testing a Hydraulic Power Pack (HPP) (10) on a test rig (20) as claimed in claim 8, wherein in the forward motion configuration of the HPP (10), pressurized oil is supplied to the first connection opening (25) and oil flows back to HPP (10) through the second connection opening (26).
10. A method of testing a Hydraulic Power Pack (HPP) (10) on a test rig (20) as claimed in claim 8, wherein in the reverse/astern motion configuration of the HPP (10), pressurized oil is supplied to the second connection opening (26) and oil flows back to HPP (10) through the first connection opening (25).
11. A method of testing a Hydraulic Power Pack (HPP) (10) on a test rig (20) as claimed in claim 8, wherein the test parameters include oil flow rate, oil pressure, oil temperature and current drawn by a drive motor (11) of the HPP (10).