Enclosure for Advanced Component Testing

Turnkey Engineering for Volatile Fuel Components Testing

To expand its engine part validation capabilities, a manufacturer required a specialized, free-standing enclosure capable of running hazardous fluid trials without allowing technicians to enter the volatile test zone. ACS delivered a turnkey, dual-sided test enclosure that fully isolates operators while strictly conforming to industry standards for fire, pressure, and acoustic containment. By integrating an Allen Bradley PLC for real-time safety monitoring, engineering custom roll-up docking carts for material handling, and managing the project from initial design through Factory Acceptance Testing (FAT), ACS provided a safe and scalable testing asset that successfully brought the client’s complex testing operations online.

The Challenge

In response to evolving market demands, a manufacturer required a specialized, free-standing enclosure to expand its capabilities in testing critical engine parts under rigorous conditions. The project presented complex technical demands, as the testing process involved utilizing a wide variety of volatile mediums, necessitating a specialized approach to alternative fuel handling. To ensure maximum operator safety, the company’s strict requirement dictated that the system must function as a unitary test enclosure that does not allow operators to physically enter the testing zone. The client lacked the specialized in-house engineering and manufacturing resources to develop an isolated environment capable of meeting stringent customer and industry regulations for sound transmission, fire mitigation, structural pressure, and safe fluid containment. The challenge was to deliver a highly integrated system that could seamlessly accommodate advanced component testing without compromising safety or operational efficiency.

The Solution

The first step was to analyze the compliance and safety parameters required for comprehensive fuel components testing. During this initial design phase, the ACS team established robust engineering criteria to ensure the structural integrity of the free-standing enclosure against extreme fire, pressure, and acoustic demands.

To optimize workflow and ergonomics, ACS designed a dual-sided architecture. The team integrated two large doors on one side of the test enclosure to provide seamless access to the primary test equipment, while placing the electrical panels and data acquisition systems securely on the opposite side of the rig. For specialized material handling, ACS engineered custom transfer carts that roll up and precisely dock with the enclosure, allowing for the easy, safe, and efficient transfer of test articles in and out of the cell without manual lifting.

To manage the inherent risks of advanced alternative fuel handling, the ACS team integrated a high-capacity scavenge air system to ensure continuous, proper ventilation. Control and safeties were centered around an Allen Bradley PLC. This PLC was programmed to monitor all fuel safety-related items, interface directly with the main data acquisition system, and provide a framework for future test cell temperature control supervision.

The Outcome

The ACS team successfully delivered a fully integrated, free-standing test rig capable of evaluating a diverse range of fluids within a single machine, dramatically accelerating the client’s capacity for advanced component testing. By eliminating the need for personnel to physically enter the test space, the final design achieves an unprecedented level of operator safety.

The custom-built enclosure successfully meets or exceeds all industry standards for sound transmission, fire safety, pressure containment, and precise automotive parts testing. The integration of the Allen Bradley PLC ensures that all critical safety parameters are continuously monitored, protecting both the facility and its technicians.

By handling everything from initial engineering through FAT, the ACS team provided the client with a reliable, verified roadmap and a turnkey asset that successfully establishes a new standard for alternative fuel handling and automotive parts testing validation.

Key Features

• Fully integrated test rig designed for advanced component testing across multiple fluid types in a single machine
• Unitary free-standing enclosure built to meet strict industry standards for sound transmission, fire, pressure, and safe fuel components testing
• Automated design that completely eliminates the need for operators to physically enter the volatile test environment
• Integrated Allen Bradley PLC to monitor all safety-critical items and manage alternative fuel handling ventilation systems

ACS Services

• Developed designs meeting strict compliance criteria for fire, pressure, and acoustics
• Programmed and integrated the Allen Bradley PLC to oversee critical safety systems and interface with data acquisition
• Manufactured the custom enclosure alongside specialized roll-up docking carts for safe material transfer
• Conducted FAT to validate and ensure the system was fully operational before delivery