End-to-end engineering, built for reliable production
Expert services to reduce technical risk, accelerate validation, and support manufacturing.
years of experience
satisfied clients
projects implemented
FR Prototypes is an experienced team of mechanical, electrical, and software engineers in the aerospace sector, dedicated to the art of the “working solution.” Historically, our work has required us to deliver fast, reliable results that take every detail into account. This has become our philosophy — one our customers value.
Turbopump Unit Test Stand
For a leading propulsion components manufacturer, we developed the electrical and software part for a turbopump test stand. The mechanical structure was already built, and the customer required a solution for high-frequency data measuring and logging with simultaneous control of flow parameters.
The system had to execute start, stop, and emergency sequences, as well as provide visualisation with analysis of vibration level at a dedicated frequency.
Challenge
The solution had to be mobile and fully operational within just a few hours after unpacking. It was designed to work reliably in harsh environments with high humidity and low temperatures. The system needed to support up to 30 sensors, with the possibility of further expansion. It also required hard real-time control of emergency sequences, ensuring guaranteed start and execution times. Additionally, remote operation was essential, with approximately 30 meters between the operator and the device under test.
Solution
For sequence control and high-frequency data acquisition was selected cRIO-9045 controller from National Instruments that is mounted in the portable case with connectors for quick sensors connection.
The system supports data acquisition from high-speed pressure sensors, RTD temperature sensors, turbine-type flow sensors, and vibration sensors with frequencies up to 40 kHz. The controller includes available slots for future expansion.
Control sequences are executed on the FPGA level to ensure hard real-time performance and maximum reliability. The operator manages the process remotely via LabVIEW application running on a laptop, with Ethernet communication enabling operation well beyond the required 30-meter distance.
Vibration levels are monitored in real time using FFT visualisation. All data is logged in TDMS and CSV formats for further analysis, and can be displayed live in independent charts or table views.
Impact
1 month
from concept to operational deployment
3 years
work in harsh environmental conditions
Fully mobile
solution delivering the capabilities of a stationary test stand
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