Sponsored by Vitrek, LLCReviewed by Maria OsipovaApr 9 2026
A wide range of aerospace test cells in the commercial, military, and defense sectors continue to rely on aging analog instruments. These instruments are functional, but they do introduce risk via factors such as the use of legacy components, calibration challenges, and a lack of digital data access.
Image Credit: Vitrek, LLC
However, testing demands are evolving, prompting the industry to shift towards compact, digital platforms designed to improve data usability and simplify workflows.
A Vitrek customer faced this challenge across multiple engine test cells. The customer addressed this issue by replacing two legacy systems with a single PBS eXpress R+. This approach enabled digital data acquisition, faster setup, and automated reporting.
The Challenge
The customer’s test cells were developed around a mix of aging instrumentation, including Endevco 6634C signal conditioners, TrigTek tracking filters, and a Dactron vibration monitoring system.
These systems were functional but lacked the flexibility required for modern workflows while proving increasingly difficult to support.
The customer’s goal was not a practical, drop-in modernization, but a complete redesign. This required the implementation of a system suitable for integration into existing environments while also offering expanded capability.
Key requirements for this project included:
- A two-speed (tachometer) input and four vibration channels
- Three 0–10 V DC order-tracked outputs
- Pre-configured engine parameter sets
- In-place calibration
- A starting cost of $20 K
The customer also required a system that could be scaled across multiple test cells, as well as simplify technician workflows without further system complexity.
Phase 1: Replacing Legacy Tracking Filters
Vitrek began by replacing obsolete tracking filters across five test cells. Vitrek’s compact system is built on PBS 4100+ technology, delivering digital order tracking, one-shot balancing, and vibration analysis.
The platform replicated legacy functionality, as well as improving usability and implementing digital data output. The platform was also deployed in additional test cells, standardizing the environment and replacing existing signal conditioners.
Phase 2: Replacing Dactron Monitoring
Because PBS was already being used to generate digital vibration data, the customer opted to expand its role. Vitrek implemented a custom software enhancement designed to support monitoring and reporting workflows that had previously been managed by Dactron.
This transformation saw PBS eXpress R+ take on a more comprehensive role as a centralized platform for data acquisition and reporting.
Results
The replacement of legacy tracking filters with digital order tracking resulted in enhanced measurement consistency and flexibility across test cells. Vibration monitoring capabilities were also expanded into additional test environments, allowing the customer to standardize operations across the facility.
The PBS eXpress R+ reduced setup time and overall operational complexity by consolidating multiple legacy systems into a single platform. The shift to digital data acquisition also allowed the use of automated reporting, enhancing both data accessibility and efficiency.
New capabilities like Ethernet-based control, seamless integration, remote access, and integration with existing reporting tools resulted in a more scalable and connected test environment.
Modernizing Without Rebuilding
- Drop-in replacement: Fits existing test cells while replicating legacy functionality. It is now also available with digital performance.
- System Consolidation: One single platform now replaces tracking filters, signal conditioners, and monitoring systems.
- Digital workflows: Users can obtain faster, more reliable results thanks to automated data collection, storage, and reporting.
- Fast deployment: The system can be quickly implemented with minimal disruption and training. The actual implementation is straightforward, and existing operations are minimally disrupted. The majority of teams can be up and running within just a few days thanks to intuitive software tools like Trim Balance WizardTM, which reduce training time and enhance ROI.
Conclusion
The PBS eXpress R+ enabled Vitrek’s customer to modernize its test cells without the risk, cost, or disruption of a complete system overhaul.
The replacement of multiple legacy analog systems with a single, flexible digital platform resulted in a more simplified test architecture while also improving workflow efficiency and measurement capability.
The transition eliminated dependence on obsolete hardware, reduced setup time, and introduced automated data acquisition and reporting. These improvements led to a more repeatable and consistent process across all test cells.
Notably, the platform offers the customer the flexibility to adapt in line with evolving testing requirements, supporting new configurations, engines, and data requirements without additional system complexity.
These capabilities result in a cost-effective, streamlined, and scalable test environment that has been developed to ensure long-term reliability and enable future growth.
This information has been sourced, reviewed, and adapted from materials provided by Vitrek, LLC.
For more information on this source, please visit Vitrek, LLC.