EDTAB

Serial hydraulic power units for electrical testing

HydTec developed a scalable hydraulic power-unit platform for EDTAB’s electrical test systems and has subsequently engineered and manufactured recurring batches in 110 kW and 160 kW versions. Each unit is assembled, configured and commissioned before delivery, with unit-specific hydraulic documentation and, for recent builds, verified pressure, flow and hose-test records.

Challenge:

EDTAB needed a compact and repeatable hydraulic solution capable of loading different electrical test systems while accommodating high power, long non-conductive hoses, restricted installation geometry and evolving requirements across successive machines.

Delivery

HydTec delivered complete custom hydraulic power units, including system sizing, 3D engineering, tanks and frames, integrated drivetrains, piping, cooling, filtration, controls, non-conductive hose assemblies, workshop commissioning and as-built documentation.

Results

An initial one-off requirement was developed into a repeatable production platform for 110 kW and 160 kW systems. Successive batches have been manufactured using controlled production instructions, with recent units individually commissioned and documented and production feedback incorporated into later machines.

GO TO RESULTS

Two large HydTec hydraulic power units on blue metal bases in a warehouse setting, with a branded crate in the foreground and a worker standing near the right side.

Initiation

Silver "HydTec" branded pen resting on a printed hydraulic circuit schematic.

Initial assessment

EDTAB approached HydTec after an existing hydraulic loading arrangement could not consistently provide the required electrical test output. HydTec reviewed the measured operating data, including pressure, flow, rotational speed, generator load and duty cycle.

The assessment showed that simply reproducing the previous arrangement would not provide sufficient operating margin or a suitable basis for future machines. HydTec therefore proposed a scalable architecture with a standardised pump platform, allowing the hydraulic motor, settings and selected interfaces to be adapted for different output levels while retaining the main system concept.

Communication

The work was coordinated through continuous technical dialogue covering operating data, interfaces, delivery priorities and changes between individual units.

HydTec maintained the CAD models, hydraulic schematics, bills of materials, manufacturing and coating instructions, assembly guidance, system settings and unit-specific commissioning records. Customer handover packages include as-built hydraulic documentation and, where applicable, pressure-test records and traceability for the non-conductive hose assemblies.

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Process

Cross-section of the bent axis piston pump used in HydTec's hydraulic power unit for EDTAB's electrical test system.

Design & Engineering

HydTec converted EDTAB’s functional test requirements into a hydraulic drive system sized from measured electrical output, generator speed, operating pressure, flow and duty cycle. The architecture was deliberately designed for reuse: a common variable-displacement pump platform supports different machine ratings, while the hydraulic motor, settings and selected interfaces are adapted to the required load point.

The complete installation was packaged in 3D, including the custom tank and frame, drivetrain alignment, piping, cooling, filtration, level and temperature monitoring, service access, lifting points and interfaces for EDTAB-supplied equipment. Height, connection positions and footprint were adjusted to suit the surrounding test installation and acoustic enclosure.

Later builds incorporated updated CAD models, hose routing, fabricated parts and experience from previous units. The documented variants use 110 kW or 160 kW electric drives. Recent 110 kW units use a Parker PV180 pump and Parker F12-152 hydraulic motor, with the pump commissioned to the documented pressure and flow limits for the series.

Manufacturing

HydTec manages the work as a controlled series-production process rather than as repeated one-off fabrication. Steelwork is prepared from the released design and then masked, sealed and coated according to defined instructions. Components and the drivetrain are assembled on the finished structure, custom pipes are manufactured and fitted, hoses and identification plates are installed, and tightened connections are marked for inspection.

Production instructions cover cleanliness, mounting sequence, coupling installation, drivetrain clearance, routing and final checks. Hose assemblies are pressure-tested and documented, while dedicated test instructions define pressure-holding and leakage checks for critical hydraulic blocks.

Each completed unit is filled, started and adjusted in HydTec’s workshop. Pressure, flow, temperature and relevant drive parameters are recorded in a unit-specific commissioning document. Experience from previous machines is incorporated into subsequent builds through improved supplier preparation, updated routing, removal of unnecessary features and increased component standardisation.

A large custom-built metal cabinet or enclosure made of brushed steel sheet metal, shown on a wooden workbench in a workshop environment.

Results

A large industrial hydraulic power unit with a blue base, electric motor, and multiple red and black hydraulic hoses, photographed in a workshop or factory setting.

Installation & commissioning

HydTec completes the mechanical and hydraulic assembly, initial start-up, parameter adjustment and documented commissioning at its own workshop before delivery.

The completed hydraulic power unit is subsequently integrated into EDTAB’s electrical test installation. HydTec can support further adjustments when operational feedback or revised test requirements make this necessary.

Follow up & support

HydTec supports EDTAB throughout successive production batches and after delivery. Operational feedback, service observations and new functional requirements are reviewed and, when technically justified, incorporated into updated drawings, production instructions, settings, test methods and future units.

This creates a controlled improvement cycle in which the established platform is retained while individual details continue to evolve.

A woman in a workshop stands beside a large hydraulic machine, with coiled hoses and industrial equipment visible in the background.

Serial hydraulic power units for electrical testing