Engine Test Rig Control System: Concept Through Detailed Design and Safety Engineering for an Aerospace OEM
Sector:
Aerospace & Defence
Type:
New Build - Control System, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl delivered a full control system engineering service for a specialist engine test rig, covering concept design, detailed electrical design, software requirements definition, control panel build, and safety engineering support. The project was structured to align with the customer's formal system gate review process, with DelaControl providing engineering continuity from initial concept through to detailed design and safety assessment.
Challenge
The customer required a complete control system for a new engine test rig, developed in accordance with a structured system gate review process defined by the end-use programme stakeholder. The control system needed to manage a complex mix of analogue, digital, high-speed, and safety-rated signals, alongside servo motor control for stall relief and throttle functions, and network connectivity to a range of rig sub-systems.
At the outset, several aspects of the project — including the full machinery safety requirements — were not yet fully defined, requiring the control system architecture to be developed iteratively as the programme matured. The customer also needed support to conduct a formal risk assessment in accordance with BS EN ISO 12100, and to develop a control philosophy from a review of system requirements.
Solution
DelaControl structured the engagement into defined phases aligned to the customer's system gate process. The initial phase produced a concept design and I/O schedule; the subsequent detailed design phase delivered a full electrical drawing pack — created in EPlan and supplied in both native and PDF formats — covering the main control panel (MCP), a rig operator control PC workstation, and a wall-mounted network switch cabinet. A software requirements specification was also developed collaboratively, and a software overview presentation was produced to define the control philosophy ahead of full software development.
The main control panel was designed as a floor-standing, three-bay enclosure housing a Siemens S7-1200 series PLC with a comprehensive I/O complement including safety-rated digital inputs and outputs, analogue I/O, and high-speed digital inputs. Two Siemens SINAMICS V90 servo drives were included for throttle and stall relief motor control, alongside a Siemens SINAMICS DCM DC converter. Thirty motor protection circuit breakers and associated safety contactors were provided for DOL motor circuits. A Siemens TP1500 HMI was integrated into the panel for local operator interaction, and an IXON IXrouter3 IoT gateway was included to support remote connectivity.
The rig operator control PC was specified as a tower PC with dual monitors and full ancillaries, enabling remote monitoring and control from a dedicated operator desk. The network switch cabinet was designed as a 19-inch rack-mounted wall unit with capacity for 32 Ethernet connections, supporting data collection from the rig's temperature and pressure instrumentation modules.
In a later phase, DelaControl provided extended engineering support including a gap analysis against the applicable design type approval requirements, assistance with risk assessments conducted in accordance with BS EN ISO 12100 and BS EN ISO 13849, generation of a control philosophy document from the requirements review, and controls-focused project management support.
Key Facts
• Siemens S7-1200 PLC platform with safety-rated I/O (F-DI and F-DQ modules)
• I/O complement: 32 digital inputs (inc. 8 high-speed), 32 digital outputs, 48 analogue inputs, 8 analogue outputs, 16 safety dual-channel inputs, 16 safety dual-channel outputs
• Two Siemens SINAMICS V90 servo drives (0.75 kW each) for throttle and stall relief motor control
• Siemens SINAMICS DCM DC converter, 400V 3AC input, 174A
• 30 motor protection circuit breakers and 30 safety contactors for DOL motor circuits
• Siemens TP1500 HMI integrated into main control panel
• Three-bay floor-standing Rittal enclosure (800W x 2000H x 400D per bay) with RiLine busbar system
• 32-port wall-mounted network switch cabinet for Ethernet signal collection
• IXON IXrouter3 4G/Wi-Fi IoT gateway for remote connectivity
• Risk assessment support delivered in accordance with BS EN ISO 12100 and BS EN ISO 13849
• Electrical drawing pack produced in EPlan, supplied in native and PDF formats
• Spares listing with component criticality ratings provided in Microsoft Excel