VAROC Air Dynamometers

Portable Turboshaft Engine Testing in Any Climate

The VAROC Air Dynamometer has been used by military and commercial organizations throughout the world for over 25 years. It has established a new standard for testing turboshaft engines for helicopters, power generation and marine applications. Branches of the US military use the VAROC to test Apache, Black Hawk, and Chinook engines before they are reinstalled to help ensure the safety of the pilots and crew. Recently, the Swedish Navy purchased a VAROC to to help with their Visby Class Corvette, the first vessel in the world to have fully developed stealth technology.

The VAROC family of air-brakes, V35, V35/85, and V250, provide an accurate, easy-to-use, easy-to-maintain, compact, lightweight, and highly reliable test capability to measure the performance of turboshaft engines ranging from 50 hp to 18,000 hp.

V35 Dynamometer testing helicopter enginesConcepts NREC's V35 Dynamometer is configured for testing Helicopter engines in high altitude / low temperature conditions. The custom gearbox and pedestal style torquemeter are used to maximize drive-line performance.

V250 Dynamometer testing a T55 Chinook engine for the US ArmyConcepts NREC's V250 Dynamometer testing a T55 Chinook engine at one of the U.S. Army’s several indoor/outdoor facilities located around the world.

Our patented product design uses ambient air as the fluid medium, which provides significant advantages over other types of dynamometers, including water brakes. Some of the VAROC Air Dynamometer benefits are:

  • Can be installed in fixed test-cell installations or used in mobile field applications
  • Does not require extensive support equipment
  • Can operate in any climate 
  • No potentially hazardous materials produced, so no need for contaminated water remediation, etc.
  • Easy to operate & maintain

V35 dynamometer testing an Apache EngineConcepts NREC's V35 testing a T700 Apache Engine in the field.

 

Concepts NREC V35 Dynamometer testing a T58 Sea King Engine

V35 Dynamometer testing a T58 Sea King Engine at one of the U.S. Navy’s several indoor/outdoor facilities located around the world.

Varoc Air Dynamometer from Concepts NREC

Concepts NREC's V35 set up on the flight line for outdoor testing in the winter.

partner-bg-img

Introduction to VAROC Air Dynamometers

Add/replace with shop tour video hosted on Youtube

Capabilities

Concepts NREC’s manufacturing capabilities extend far beyond simply cutting metal. Our highly skilled machinists are backed by experienced design engineers with diverse technical backgrounds and software engineers who have produced industry-leading CAE and CAM programs. This broad expertise enables us to suggest more efficient manufacturing methods, materials, processes, and designs that meet customer needs while lowering their production costs.

2Pc_Braized_Shrouded_Impeller__SI_Turbine_Family_DSC_0228_5NB.jpg

 

 

 

State-of-the-Art Machine Tools and Technologies

Concepts NREC operates a state-of-the-art product center capable of producing the highest-quality, precision-machined turbomachinery components and assemblies. Drawing on extensive experience and expertise with materials, industries, and technologies, Concepts NREC succeeds at complex component challenges that typically have been problematic for others.

This knowledge is supported by the latest manufacturing technologies that, combined, provide Concepts NREC with the credentials to meet the most exacting customer requirements across many industries including aerospace, energy, and industrial processing

Capabilities

  • 5-axis machining of blades, blisks, inducers, propellers, impellers, and other turbomachinery parts
  • Component assembly
  • Concurrent manufacturing/engineering
  • Coordinate Measuring Machine (CMM) inspection
  • Dynamic balancing and modal analysis
  • Inspection and testing to validate integrity and performance
  • Machining complex shrouded (enclosed) impellers for pumps and compressors
  • Prototypes and shorter production runs
  • Reverse engineering of obsolete parts

manufacturing capabilities statement 2

 


Your Trusted Partner

Our design and manufacturing capabilities make us the first choice for many of the world’s leading manufacturers.

  • Large OEMs trust us to concurrently engineer/manufacture the blisks and vanes for their newest product designs.
  • International pump companies rely on us for our consistent quality and timeliness with their shrouded (enclosed) impellers.
  • Users across a broad spectrum of industries leverage our expertise to reverse engineer obsolete turbomachinery parts.
  • Early-stage start-ups work with us to build and improve their prototypes.     

    

What We Offer

Capabilities

  • Simultaneous 5-Axis up to 39 in (99.06 cm) diameter
  • Turning up to 39 in (99.06 cm) diameter
  • CMM Inspection with Zeiss Blade Pro for in-depth dimensional analysis of turbine blades
  • Assembly & Testing

Services

  • Heat Treat
  • Wire/Sinker EDM
  • Spline/V-tooth/Drive Pins/Polygon
  • Grinding
  • Abradable Coating
  • Brazing
  • Polishing
  • Shot Peening
  • Paint
  • Passivation
  • Electroplating
  • Welding
  • Dynamic Balancing
  • Overspeed Testing
  • Liquid Penetrant Testing
  • Ultrasonic Testing
  • Laser Scanning
  • Additive Manufacturing

Materials

  • Aluminum
  • Stainless Steel
  • Inconel
  • Titanium

Part Types

  • Pump Impellers (open & integrally shrouded)
  • Compressor impellers (open & integrally shrouded)
  • Turbines rotors/impellers
  • Blisks
  • Housings/Volutes
  • Bladed stators/guide vanes (IGVs)
  • Diffusers
  • Shrouds

Tolerances

  • Dimensional to +/- 0.0001”
  • Surface finishes to 8 µ in Ra

Trust the Experts in Turbomachinery

For over 60 years, we have helped leading global OEMs to improve the performance and manufacturability of their turbomachines.

This is a video of Concepts NREC's optional 3+2 Roughing Module that enables roughing out of impellers using 3-axis algorithms, keeping a constant tool vector. This strategy optimizes the toolpath to provide constant cutting load, making it suitable for high speed machining. This is extremely helpful for large (>0.5 m) diameter impellers and/or hard materials where roughing using the 5-axis strategies is less efficient.

Below is a video of Concepts NREC's optional 3+2 Roughing Module that enables roughing out of impellers using 3-axis algorithms, keeping a constant tool vector. This strategy optimizes the toolpath to provide constant cutting load, making it suitable for high speed machining. This is extremely helpful for large (>0.5 m) diameter impellers and/or hard materials where roughing using the 5-axis strategies is less efficient

Below is a video of Concepts NREC's optional 3+2 Roughing Module that enables roughing out of impellers using 3-axis algorithms, keeping a constant tool vector. This strategy optimizes the toolpath to provide constant cutting load, making it suitable for high speed machining. This is extremely helpful for large (>0.5 m) diameter impellers and/or hard materials where roughing using the 5-axis strategies is less efficient.

Below is a video of Concepts NREC's optional 3+2 Roughing Module that enables roughing out of impellers using 3-axis algorithms, keeping a constant tool vector. This strategy optimizes the toolpath to provide constant cutting load, making it suitable for high speed machining. This is extremely helpful for large (>0.5 m) diameter impellers and/or hard materials where roughing using the 5-axis strategies is less efficient.

Here are some quotes from our Customer Satisfaction Survey sent out after every job:

  • "Customer service is really good - they answer questions and concerns in a timely manner."
  • "High performance from quote to delivery"
  • "Concepts' decision to stock material that is qualified to our specifications is a great competitive advantage. Their willingness to provide technical / commercial informational support makes them my "go-to" supplier for milled impellers."

Agile Products Support (APS)

APS is Concepts NREC’s software maintenance and support program that elevates us from just a software provider to a valued partner. 

An APS subscription is included with all annual licenses and is a highly-recommended option for perpetual software licenses. Every software customer is supported for one month following purchase for any installation questions that may arise. Learn more on the Agile Products Support Membership Benefits Datasheet

  • Free software updates
  • One business day response times
  • Expert technical assistance
  • Major discounts on software workshops
  • Discounted professional development course
  • Annual balloting system for development planning
  • Annual Meetings

VAROC Air Dynamometers Brochure

For reliable, low-maintenance load testing of gas turbine engines

Dyno Cut Sheet_R2

Related Blog Articles

Meet Claudio Raia
CAE Software
Meet Claudio Raia
by Kate Guerrina, Marketing Manager
Dave Schowalter, Director of Global Software Sales, introduces you to Claudio Raia, our newest team member and the Managing Director of Concepts NREC Europe. Welcome Claudio!
Continue Reading
What Are the 5 Axes in 5 Axis Machining?
CAM Software
What Are the 5 Axes in 5 Axis Machining?
by Christos Maninos, CAM Application Engineer & Peter Klein, Director, CAM Software
What is 5 axis machining? In short, it is manufacturing a component on a CNC milling machine that can travel in 5 different directions. These machines allow the cutting tool to reach around parts with a high degree of freedom. This makes them ideal for milling the complex shapes of turbo machinery components.
Continue Reading
Increased Milling Capability and Capacity for Large 5-Axis Impellers
MAX-PAC
Increased Milling Capability and Capacity for Large 5-Axis Impellers
by Sean McDermott
Concepts NREC has added two additional Hermle 5-axis mills in our shop, and we’re excited  about the increased capabilities these new machines bring! In August of 2018 we received the  first of these mills, a 2018 Hermle C52uMT.  Just recently, in May of 2019, we added a Hermle C42u.  In addition to these new, state-of-the-art 5-axis Hermle mills, our shop utilizes a Mikron HSM600U, good for parts up to ~13” in diameter; a Hermle C40, which can mill parts up to ~20” in diameter, and a Mitsui Seiki HS5A-80, which can handle larger parts, up to ~32” in diameter.  We now have a full range of  5-axis mills capable of producing the most challenging parts from >1 inch up to over 39 inches in diameter.  
Continue Reading