Introduction
Many military/defense and commercial aerospace test cells still rely on aging analog instruments that, while functional, introduces risk through calibration challenges, legacy components, and lack of digital data access. As testing demands evolve, the industry is moving toward compact, digital platforms that simplify workflows and improve data usability.
A Vitrek customer faced this challenge across multiple engine test cells. Their solution: replace two legacy systems with a single PBS eXpress R+, enabling faster setup, digital data acquisition, and automated reporting.
The Challenge
The customer’s test cells were built around a mix of aging instrumentation, including TrigTek tracking filters, Endevco 6634C signal conditioners, and a Dactron vibration monitoring system. While functional, these systems were increasingly difficult to support and lacked the flexibility required for modern workflows.
The goal was not a complete redesign, but a practical, dropin modernization—a system that could integrate into existing environments while delivering expanded capability.
Key requirements included:
- 2 speed (tachometer) inputs and 4 vibration channels
- (3) 0–10 V DC order-tracked outputs
- Pre-configured engine parameter sets
- In-place calibration
- Starting at $20K
Beyond specifications, the customer needed a system that could scale across multiple test cells and simplify technician workflows without adding complexity.
Phase 1 — Replacing Legacy Tracking Filters
Vitrek brand) replaced obsolete tracking filters across five test cells. Built on PBS 4100+ technology, it delivers digital order tracking, vibration analysis, and one-shot balancing in a compact system.
The platform not only replicated legacy functionality but improved usability and added digital data output. It was also deployed in additional test cells, replacing existing signal conditioners and standardizing the environment.
Phase 2 — Replacing Dactron Monitoring
With PBS already generating digital vibration data, the customer expanded its role. Vitrek developed a custom software enhancement to support monitoring and reporting workflows previously handled by Dactron.
This transformed PBS eXpress R+ into a centralized data acquisition and reporting platform.
Results
Legacy tracking filters were replaced with digital order tracking, improving measurement flexibility and consistency across test cells. At the same time, vibration monitoring capabilities were expanded into additional test environments, allowing the customer to standardize operations across their facility.
By consolidating multiple legacy systems into a single platform, the PBS eXpress R+ reduced setup time and overall operational complexity. The transition to digital data acquisition also enabled automated reporting, improving both efficiency and data accessibility.
In addition, new capabilities such as remote access, Ethernet-based control, and seamless integration with existing reporting tools provided a more connected and scalable test environment.
Conclusion
The PBS eXpress R+ enabled the customer to modernize their test cells without the cost, risk, or disruption of a full system overhaul. By replacing multiple legacy analog systems with a single, flexible digital platform, they simplified their test architecture while improving measurement capability and workflow efficiency.
The transition reduced setup time, eliminated dependence on obsolete hardware, and introduced automated data acquisition and reporting—creating a more consistent and repeatable process across all test cells. Just as importantly, the platform provides the flexibility to adapt as testing requirements
evolve, supporting new engines, configurations, and data needs without additional system complexity.
Result: a streamlined, cost-effective, and scalable test environment built for long-term reliability and future growth.
