Test Infrastructure & Lab Design

🎯 Service Scope: Operational Requirements & Integration Design, Not Detailed Engineering Specifications

What this service covers: Defining operational requirements (what the facility needs to do), test lab layout planning, power architecture design, DAQ/instrumentation integration, control system setup, network architecture, data storage design, and equipment selection. We design WHERE things go, HOW they connect, and WHAT operational capabilities you need.

What this service does NOT cover: Detailed engineering specifications (bolt sizes, concrete mix, slab thickness, rebar design), mechanical fixture design (CAD drawings of test fixtures), structural engineering calculations, or detailed electrical panel design. We specify operational requirements; specialists execute the detailed design and build.

Why Teams Need Test Infrastructure Planning

"We need to set up a test lab but don't know where to start"

You have test equipment arriving, but no plan for lab layout, power distribution, DAQ integration, or data storage. Setting up ad-hoc creates safety issues and workflow bottlenecks.

"Our power calculations don't add up and we keep tripping breakers"

Without proper power architecture planning (considering power factor, device efficiency, peak loads), facilities can't support your test program. You need accurate load calculations before requesting facility power.

"We lost test data when facility power went down"

No backup power strategy means facility outages wipe test data and damage equipment. Test labs need UPS systems and emergency shutdown procedures to protect data and hardware.

"Our DAQ system talks to some equipment but not others"

Without integrated network architecture planning, equipment can't communicate. Test labs need isolated networks with proper Ethernet topology, IP addressing, and failover strategies.

What You Receive

Test Lab Layout & Infrastructure Design

Complete lab design showing equipment placement, power distribution, network topology, and workflow optimization

Lab layout plan - Equipment station locations, operator workstations, visitor viewing areas, surface plate/mounting locations
Power architecture design - AC/DC power distribution (120VAC, 240VAC, 480VAC, 12V, 24V, 28V, DC voltages as needed), load calculations with power factor and efficiency, outlet locations (15A, 20A as required), backup power (UPS) sizing and placement
Network architecture diagram - Isolated LAN design (separate from company network for safety-critical control), Ethernet topology showing DAQ, controllers, PCs, switches, IP addressing scheme, redundancy/failover strategy
Safety systems - Emergency stop button locations, power isolation points, blade protection barriers (e.g., carbolaminate partitions for rotating equipment), remote control requirements (control room → test stand)
Outdoor test pad requirements (if applicable) - Operational requirements: need for anchor points (where, what loads), underground power outlet locations, cable routing (control room to test stand), equipment clearances. NOTE: Structural engineer uses these operational requirements to design concrete pad (slab thickness, anchor bolt specifications, rebar reinforcement, etc.)

Format: PowerPoint, Visio, or PDF (client's choice), 15-30 slides/pages depending on scope

DAQ & Instrumentation Integration Design

Complete data acquisition and instrumentation architecture with equipment specifications

DAQ system specification - Module selection (e.g., Dewesoft configuration), channel count and sampling rate requirements, measurement types (voltage, current, temperature, load, pressure, RPM, etc.)
Sensor selection and placement - Sensor types (load cells, thermocouples, pressure transducers, current sensors, etc.), mounting locations and considerations, calibration/verification approach
Signal routing and conditioning - Cable runs and connector types, signal conditioning requirements (amplifiers, filters, isolation), grounding and shielding strategy
Equipment integration - How DAQ connects to power supplies, controllers, and test articles, Ethernet/USB/serial communication protocols, Software interface requirements

Format: PowerPoint, Visio, or PDF, 10-20 slides/pages

Data Storage & Backup Architecture

Data storage system design with redundancy and backup strategy

Storage system specification (e.g., Synology NAS with RAID redundancy)
Capacity sizing based on test data volume
Backup strategy (local redundancy + offsite/company server backup)
Data retention and archival approach
Network isolation (test data server separate from company network)

Equipment List with Part Numbers

Complete bill of materials for infrastructure setup

Computers, monitors, and operator interface equipment
DAQ hardware (modules, chassis, accessories)
Network equipment (switches, routers, cables)
Power supplies and distribution units
UPS systems for backup power
Ancillary equipment (mini cranes, carts, safety equipment)
Vendor part numbers and approximate pricing

Facility Coordination Package

Requirements documentation for facility manager and contractors

Electrical requirements (voltage, amperage, breaker sizing) for facility electrician
Network/IT requirements (if facility IT support is involved)
Space requirements (dimensions, clearances, access)
Operational requirements (anchor point needs with loads, underground power outlet locations, cable routing) - structural/civil engineer uses these to design foundations, slabs, bolt specifications, etc.
Safety and code compliance considerations

Optional Add-Ons

Installation Support

On-site support during equipment installation and integration to ensure setup matches design intent

System Commissioning

Post-installation checkout, DAQ calibration verification, and operator training

How It Works

1

Requirements Discovery

Review test program objectives, test types, measurement needs, and operational constraints. Identify facility and infrastructure requirements.

2

Architecture Development

Define instrumentation architecture, facility layout concepts, and equipment categories. Map requirements to vendor options.

3

Vendor Research & Selection

Research equipment vendors, evaluate product families, compare capabilities and pricing. Create vendor recommendation matrix.

4

Documentation & Handoff

Deliver infrastructure requirements, instrumentation architecture, vendor recommendations, and facility layout concepts with walkthrough.

Test Lab Types We Support

Propulsion Test Infrastructure

Outdoor test pads: Full-scale propulsion testing, operational requirements (anchor point needs, underground power, cable routing), power generation (portable generators), remote control from control rooms

Indoor test cells: Sub-scale propulsion testing, blade protection barriers (carbolaminate partitions), controlled environment testing

Multi-Purpose Test Labs

Hangar/facility conversion to test lab, multiple test stations in shared space, shared infrastructure (power, DAQ, network), surface plate mounting configurations for various test articles

Component Test Benches

Actuator performance testing (blade pitch, control surfaces), load measurement and verification, sensor calibration/checkout stations, functional verification test setups

Control Room Design

Operator workstation layout, multi-monitor configurations, visitor viewing areas with video displays, equipment rack placement, remote control interfaces for test stand operation

Power Distribution Systems

AC power (120VAC, 240VAC, 480VAC), DC power (12V, 24V, 28V, up to 750VDC), portable and facility power coordination, backup power (UPS) systems, emergency shutdown circuits

Data Acquisition & Control Networks

Dewesoft-based DAQ systems, isolated safety-critical networks, Ethernet/LAN topology design, real-time control integration, data storage with redundancy

Who This Is For

✓ Best Fit For:

Engineering teams planning new test facilities
Programs expanding existing test infrastructure
Startups building first test capability
Teams needing vendor-neutral equipment recommendations
Programs transitioning from prototype to production testing
Organizations needing infrastructure requirements before RFQ

✗ Not a Fit For:

Teams needing full MEP engineering design
Projects requiring PE-stamped drawings
Detailed electrical or HVAC design
Custom DAQ software development
Facility construction management

4-8 Weeks

Typical engagement duration, depending on lab complexity and equipment scope

What Affects Timeline:

• Lab type and size (single test stand vs. multi-purpose facility)
• Number of test stations (one setup vs. multiple integrated stations)
• Instrumentation complexity (basic DAQ vs. high-channel-count synchronized systems)
• Power requirements (standard facility power vs. custom AC/DC distribution design)
• Existing infrastructure (greenfield vs. retrofit/upgrade of existing lab)

Frequently Asked Questions

Will you design our test lab in detail with CAD drawings?

We provide lab layout plans, power distribution diagrams, and network architecture—typically in PowerPoint or Visio format. We specify WHERE equipment goes, HOW it connects, and WHAT power/network/DAQ it needs. We do NOT provide detailed CAD models of mechanical test fixtures, structural calculations, or PE-stamped engineering drawings. Our deliverables give contractors and specialists the requirements they need to execute the build.

Do you do the actual installation and setup?

The base service is design only. However, we offer optional installation support as an add-on, where we can be on-site during equipment installation to ensure setup matches design intent. We can also provide system commissioning (post-installation checkout, DAQ calibration verification, operator training).

What's the difference between your service and hiring a facilities engineering firm?

We focus on test-specific infrastructure: DAQ integration, test equipment layout, control systems, instrumentation architecture, and test workflow optimization. Facilities engineering firms handle building systems: HVAC ductwork, electrical panel design, structural calculations, plumbing, and code compliance. Our deliverables specify requirements FOR the facilities engineers, electricians, and contractors to execute.

Do you work with specific DAQ brands?

We have extensive experience with Dewesoft systems (module selection, configuration, integration). We can work with other DAQ platforms if you already have equipment, but Dewesoft-based designs are our primary expertise.

Can you design power distribution for outdoor test pads?

Yes. We've designed power architectures for outdoor propulsion test stands including portable generator sizing (with power factor and efficiency calculations), AC/DC distribution, backup power (UPS), and coordination with facility electricians for power drop requirements. We specify electrical requirements; electricians execute the panel design and installation.

What if we're converting an existing space into a test lab?

We can work with existing spaces. We'll assess current infrastructure (power capacity, network availability, space constraints), identify gaps, and design lab layout and upgrades to support your test program. This includes retrofitting existing rooms or hangar spaces into functional test facilities.

Do you design control rooms separate from test stands?

Yes. We design remote control room layouts including operator workstations, multi-monitor configurations, visitor viewing areas, equipment racks, and network connectivity from control room to test stand. We've designed both partitioned control rooms (within test cell with protective barriers) and separate control rooms for outdoor test pads.

Can you help with safety systems like emergency stops?

Yes. Our designs include emergency stop button placement, power isolation points for test safety, blade protection barriers (e.g., carbolaminate partitions for rotating equipment), and backup power systems to prevent data loss during facility outages. We specify requirements; electricians wire the actual e-stop circuits.

Do you provide ongoing support after delivery?

The base engagement includes one round of revisions after stakeholder review. Ongoing support (clarifications during installation, equipment acceptance testing, troubleshooting during commissioning) is available as a follow-on service or as part of optional installation support add-on.