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Design and Implementation of a Load Simulator Rig and Ground Test Bench Adaptation Kit for a HEMAS Test Rig

European Union
Complete with results
Geo-spatial type
Total project cost
€911 120
EU Contribution
€683 340
Project Acronym
STRIA Roadmaps
Vehicle design and manufacturing (VDM)
Transport mode
Airborne icon
Transport policies
Societal/Economic issues,
Environmental/Emissions aspects,
Transport sectors
Passenger transport,
Freight transport


Call for proposal
Link to CORDIS

The TESTHEMAS project designed, manufactured and tuned an innovative and smart Test Rig for linear actuators that are capable of conducting synchronised tests on three assemblies of Helicopter linear ElectroMechanical Actuators (HEMAS) while applying different counter loads on them. This functionality was controlled and monitored by means of a local control, command and data monitoring system. On the other hand, the test rig incorporated an adaptation kit able to be inserted in a global test bench simulating an aircraft network called Electrical test Bench (Copper Bird) in such a way that the test rig can be operated remotely including a very versatile data transfer capacity

This actuator test rig was based on a modular, eco-efficient and adaptive concept by integrating easily exchangeable hydraulic and mechanical components with sensors and control strategies that allow automatic and autonomous safe operation that assured optimised lifecycle costs and environmental impacts during HEMAS tests. This innovative concept of actuator test bench meant thus a positive impact on the safety and working conditions of the end users of the Test Bench as well as a reduction in the time and costs associated to testing linear actuators together with an increase in the quality and reliability of said tests.

The TESTHEMAS system was tested and validated at several stages: Virtual validation at model level and final experimental validations of the complete system. These sequential and complementary validations assured thus a reliable, safe and efficient performance of the prototype and provided data for a deep concept evaluation.


Parent Programmes
Institution Type
Public institution
Institution Name
European Commission
Type of funding
Public (EU)
Specific funding programme
JTI-CS - Joint Technology Initiatives - Clean Sky
Other Programme
JTI-CS-2012-2-GRC-03-014 Design and Implementation of a Load Simulator Rig and Ground Test Bench Adaptation Kit for a HEMAS Test Rig


Executive Summary:

TESTHEMAS includes the following results corresponding to their specific packages:

WP1 - Specifications and Requirements of the Test Rig and Adaptation Kit

  • Defined in detail with the CSJU Topic Manager the specifications and requirements associated to the HEMAS Test Rig and Adaptation Kit system.

WP2 - Test Rig and Adaptation Kit Conceptual design

  • Developed simplified models (electrical, mechanical) of the Test Rig.
  • Integrated the models of the concepts of mechanical and control components for validating the global concept of the Test Rig in a virtual manner.
  • Identified potential physical implementations and to simulate electrical and mechanical behaviour.
  • Selection of the optimal solution to be implemented.
  • Developed the concept of the Graphical User Interface.

WP3 - Test Rig and Adaptation Kit Detailed Design

  • Designed in detail the mechanical, hydraulic, electric/electronic components of the Test Rig and Adaptation Kit.
  • Designed in detail the control, monitoring and communication SW for the Test Rig and Adaptation Kit.

WP4 - Test Rig and Adaptation Kit Manufacturing, Integration and Tuning

  • Manufactured and assembled the Test Rig parts and components defined during the detailed design stage.
  • Commissioned the TESTHEMAS system and to tune the drive and control parameters once the test bench has been assembled.

WP5 - Validation and Acceptance tests

  • Defined Test Rig Acceptance Test Plan and Procedure.
  • Tested and validated the TESTHEMAS Test Rig. Execution of the Test Rig Acceptance test programme.
  • Analysed the results and compare them with the predicted results obtained in previously performed simulations. Model correlation and Test Rig and model final fine adjustment.
  • Approved the complete TESTHEMAS system at laboratory level.

WP6 - Delivery and support

  • TESTHEMAS Test Rig delivery to end user’s site. Provided assembly installation and operational support.
  • TESTHEMAS Test Rig delivery to Copper Bird site. Provided assembly installation and operational support.

WP7- Dissemination and Exploitation

  • Communicated, shared and transferred relevant knowledge about the technologies developed in the project to the European market of technology providers and end users.
  • Defined an internal exploitation strategy for the TESTHEMAS system.

WP8 – Project Management

  • In this Task, TECNALIA established an appropriate governance structure for assuring an effective project direction and management. This structure defined roles, responsibilities and activities within the organization and people involved in the Project as well as decision rules.



Lead Organisation
Fundacion Tecnalia Research & Innovation
Organisation website
EU Contribution
€683 340
Partner Organisations
EU Contribution


Technology Theme
Aircraft design and manufacturing
Electro-Mechanical Actuators (EMAs)
Development phase
Demonstration/prototyping/Pilot Production

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