Hydraulic Power Pack Manufacturer · Talwade, Pune · Since 1991
+91 98609 60006sales@suyoghydrosystems.comMon–Sat 9–6
Suyog Hydrosystems logo Suyog HydrosystemsHydraulic Power Units · Pune

Test rigs & test stands

Hydraulic Test Rig & Test Stand Portfolio

Design, build, integration and commissioning of hydraulic test stands — proven with the world's leading fluid-power OEMs.

Since 1991Talwade, PuneGlobal fluid-power OEMsUp to 700 bar
Discuss a test stand See the track record
Delivered capability
6Test stands, 2018–2025
700 barHighest-pressure build
45 kWVFD test drive
500 NmIn-line torque measurement
2 OEMsGlobal fluid-power clients
100%Repeat business

What we do

Complete test stands, engineered and built in-house

Suyog Hydrosystems is a hydraulic systems manufacturer in Talwade, Pune — in the Pimpri-Chinchwad industrial belt, 30 minutes from Chakan. Since 1991 we have engineered, built and tested hydraulic power units and complete test stands, including repeat builds delivered to reputed global fluid-power OEMs.

Each stand is delivered as one responsibility: hydraulics, structure, electricals, controls, data acquisition and safety — engineered, built, tested and commissioned by a single team, then verified on our own bench before dispatch.

  • In-house engineering — GA and structural design, BOM engineering with global component brands
  • Build & integration — fabrication, CS & SS TIG-welded piping, power-unit assembly, control panels, VFD drives, instrumentation
  • Testing & commissioning — every unit runs on our bench before dispatch, with a test certificate
  • OEM component base — authorised integrator for leading fluid-power brands; components from globally specified makes — Rexroth, HAWE, WIKA, Siemens/ABB, NI and Pilz

Test stand track record

Six test stands, engineered and built 2018–2025

Delivered to two of the world's largest fluid-power OEMs. Every figure below has been delivered on a working stand — not a proposal.

2018
Hydraulic Motor Test Stand · built for a global fluid-power OEM
420 bar · 45 kW VFD · 500 Nm in-line torque · torque–speed–efficiency DAQ
2019–20
3-Station Gear Pump Test Rig · built for a global fluid-power OEM
3 parallel stations · up to 60 LPM · 37 kW VFD production rig
2020
EDC Test Stand · built for a global fluid-power OEM
300 bar · P1M piston-pump electronic displacement control
2022
Pump Shaft-Locked Fatigue Test Stand · built for a global fluid-power OEM
350 bar cycling · proportional control · endurance / 24-7 duty
2023
Accumulator & Rotary Actuator Test Stand · built for a global fluid-power OEM
700 bar HP unit · 7× 1000-bar sensors · iCount contamination monitoring
2025
Duplex Filter Test Rig · built for a global fluid-power OEM
150 bar · dual pump circuits · spillage handling

Flagship reference

Hydraulic Motor Test Stand

Built for a global fluid-power OEM · 2018

420 bartest pressure (370 bar working)
45 kWVFD test drive + encoder
500 Nmin-line torque measurement
350 LPMmain-line flow metering

Scope highlights

  • Full performance test stand for hydraulic motors: torque–speed–efficiency mapping under controlled load
  • 90cc piston test pump on 45 kW VFD motor with speed encoder; charge, recirculation & sump pump groups (~55 kW total installed)
  • Regenerative load circuit with 55cc load motor; proportional pressure & flow control valves
  • Honeywell TMS 9250 torque sensor, speed sensors, KRAL screw flowmeters (case drain 1–30 LPM, main 1–350 LPM)
  • Industrial PC + NI data acquisition & software, VFD panel, Pilz safety relays, fully enclosed interlocked frame 5.0 × 3.0 × 2.5 m
  • 800 L overhead reservoir, 28 kW plate heat exchanger, multi-stage filtration to 5 µ

Why it matters

Proven, not promised.

A 420 bar / 45 kW hydraulic motor test stand with torque–speed–efficiency DAQ is already in our delivered portfolio — engineered with and for a global fluid-power OEM. A new motor-stand requirement lands on proven ground, not a first attempt.

Selected builds

From production rigs to 700-bar research stands

Accumulator and rotary actuator test stand built for a global fluid-power OEM

Highest-pressure build

Accumulator & Rotary Actuator Test Stand

Built for a global fluid-power OEM · 2023

700 barHP unit (radial piston)
22 kWVFD drive, 0–2000 rpm
7×1000-bar sensors
3×iCount particle detectors
  • Multi-function stand: accumulator proof & leakage testing, rotary actuator functional testing, flushing & contamination control
  • 32cc variable piston pump on VFD-driven 22 kW motor with proportional pilot control; dedicated 700 bar radial-piston HP unit with HAWE proportional relief
  • Leakage test regimes at 310 / 517 bar; automated valve sequencing (20+ solenoid operations); ISO cleanliness monitoring throughout

Endurance capability

Pump Shaft-Locked Fatigue Test Stand

Built for a global fluid-power OEM · 2022

350 barfatigue cycling pressure
37 kWmain drive motor
NG10proportional valve cycling
32 kWheat exchanger, continuous duty
  • Endurance stand: pressure fatigue cycling on locked-shaft pumps to validate structural life
  • 28cc variable piston pump; proportional directional valve executes programmed pressure cycles; dual 400-bar controllers with switching + analog outputs for cycle counting & shutdown logic
  • Thermal management sized for 24/7 duty; Ferrocare fine filtration; SS304 / CS TIG-welded piping to OEM specification
Pump shaft-locked fatigue test stand with control panel, built for a global fluid-power OEM
Duplex filter test rig built for a global fluid-power OEM

Compact / component

Duplex Filter Test Rig

Built for a global fluid-power OEM · 2025

150 bartest pressure
120 barworking pressure
2 circuitsdual pump, with spillage recovery
  • Filter body & duplex-filter changeover testing under pressure
  • 5.5 kW main + 0.75 kW spillage recovery circuit with collection tray; pressure transmitter + panel-mounted relief and metering controls
EDC compact test stand built for a global fluid-power OEM

Compact / component

EDC Test Stand

Built for a global fluid-power OEM · 2020

300 bartest pressure
200 barworking pressure
SS304seamless piping · ~1.25 × 1.25 m footprint
  • Compact stand for P1M piston-pump electronic displacement control (EDC) validation
  • 12 V DC solenoid controls; full electrical control wiring to junction box, IP-55

Production / end-of-line

3-Station Gear Pump Test Rig

Built for a global fluid-power OEM · 2019–20

3parallel test stations
60 LPMpump flow range (from 0.2)
37 kWVFD production drive
400 barstation pressure controllers
  • Production / end-of-line rig for aluminium gear pumps: one 0.2–15 LPM station + two 0.4–60 LPM stations
  • Proportional relief valve per station; SCVF flow transmitters; per-station pressure-line filtration; pneumatic pump clamping with interlocked safety door for fast changeover
  • Sump recovery unit, iCount particle monitoring, 30 kW plate heat exchanger; VFD speed control across the full test envelope with encoder feedback

Capability envelope

Proven, not promised

Every figure below has been delivered on a working test stand.

Pressure

120 – 700 barWorking & test circuits, incl. ultra-high-pressure radial-piston units

Flow measurement

0.2 – 350 LPMSCVF transmitters, KRAL screw flowmeters, case-drain metering

Drive power

up to 45 kW VFDEncoder feedback, 0–2000 rpm, Siemens / ABB class drives

Torque & speed

500 Nm in-lineHoneywell TMS telemetry torque sensing + speed pickups

Data acquisition

NI + Industrial PCPLC + HMI, 4–20 mA instrumentation, automated test sequencing

Cleanliness

ISO code monitoringiCount online particle detection, filtration to 3–5 µ

Safety

Pilz relays + interlocksEnclosed frames, door interlocks, relief protection at every stage

Test types

Performance · EOL · FatigueEfficiency mapping, leakage, endurance cycling, production testing

How we would execute your project

From requirement study to commissioning

  1. 01

    Requirement study

    Test specification review: motor range, pressures, speeds, torque, test cycles, acceptance criteria, standards.

  2. 02

    Concept & quotation

    Hydraulic circuit concept, drive & DAQ architecture, GA layout and a component make-list for your approval.

  3. 03

    Detail engineering

    Circuits, BOMs, manifolds, structure, electrical & control design — revision-controlled, submitted for sign-off.

  4. 04

    Build & FAT

    Fabrication, assembly, piping and wiring at Talwade. Factory acceptance test witnessed by your team.

  5. 05

    Install & commission

    Installation at your site, calibration, operator training, documentation handover and ongoing local support.

Component makes to your preference — any globally reputed fluid-power brand, or as specified by your standard.

Why Suyog for your test stand

OEM-grade work, 30 minutes from Chakan

We have built this before

Motor, pump, valve, accumulator and filter stands are already in our delivered portfolio — your requirement lands on proven ground, not a first attempt.

OEM-grade documentation

Global OEM build standards: revision-controlled circuits, BOMs and GAs, TIG-welded seamless piping, IP-55 wiring, factory acceptance testing.

30 minutes from Chakan

Talwade to Chakan MIDC is a short drive — design reviews at your site, fast commissioning support and lifetime service without flying anyone in.

Single point of responsibility

Hydraulics, structure, electricals, controls, DAQ and safety — engineered, built, tested and commissioned by one team, verified on our own bench.

Also engineered-to-order

Custom hydraulic systems & power units

Beyond test stands, we build fully customised hydraulic systems for demanding applications — boom luffing, stacker–reclaimer, lubrication and more.

Custom Hydraulic Systems

Get started

Let's build your test stand.

Send your test specification and our engineers will review it and present a concept and budgetary proposal.

Discuss a test stand +91 98609 60006
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