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Power Train, Research & Development · Gear test rigs |
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FWD gear test rigs for quality tests |
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Test rig at General Motors in São Paulo |
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The test rig is used for improving the quality of front-wheel drive (FWD) gears at General Motors in São Paulo. This test rig concept also supports the development of new gears. Using 3 DC generators and a switching robot, the speed and torque values that occur in the vehicle are simulated for both static and dynamic processes.
Test rig design
The test rig basically consists of the following components:
- Front generator with air/water cooling, adjustable in height by lifting spindle elements, coupling to test specimen by belt gear.
- 2 rear generators with fixed subframe in which the air-water cooler is integrated.
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| Technical Data |
| Gear input |
143 kW at 3575 to 7000 1/min
380 Nm from 0 to 3575 1/min
190 Nm at 7000 1/min |
| Gear output, per side |
105 kW at 635 to 1740 1/min
1580 Nm from 0 to 635 1/min
577 Nm at 1740 1/min |
| Shaft height |
1000 mm |
Height adjustment range
of the front generator |
950 to 1250 mm |
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All generators have sound-damping hoods. Digital shaft encoders and torque measuring flanges measure the test specimen's input and output variables directly. The gear shift is executed by a switching robot . The selection and switching paths are operated by two servo motors, a compressed air cylinder operates the clutch. A manual terminal with user guidance and teach-in functions allows fast adaptation to new test specimens. |
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Control types
Control is fully digital. The following control types are used:
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| Front generator |
Rear generator |
| Speed |
torque with differential speed (bend or straight road) |
| Torque |
speed with differential speed (bend or straight road) |
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The control covers all modern strategies for improving the dynamic such as:
- Pre-control
- Control circuit disconnection
- Adaptation
- Torsion vibration damping
Operation
The test rig has two operating options:
- Manual mode by means of three digital setpoint potentiometers and one operator panel with graphic display in which operating masks can be selected by function keys which enable user-guided control and monitoring of the test rig.
- PC mode with the CATS PC system for fully automatic testing with setpoint presetting for the different test programs and measured value acquisition, display, storage and limit value checking. The test programs can be created, changed or extended as you like. The operating dialog is via the monitor and keyboard, logging is via printer.
In addition, every generator can be operated with individual speed control in the maintenance mode.
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