| The test rig supports continuous testing of truck gear boxes with regard to optimization of life endurance, material selection, surface finish and lubricant. It is operated by the APL company in Landau.
Using two three-phase current generators, one adapter gear box and one switching robot, the speed and torque values that occur in the vehicle are simulated for both static and dynamic processes.
The test specimen can also be stressed beyond its design torque to reduce the testing time. The wear and tear of teeth and the pitting of gear cogs can be specifically tested.
The test rig is also suitable for developing new gear boxes due to its flexible control and automation concept.
Test rig design
The test rig is set up on a single, torsion-free base frame and basically consists of the following components:
- Drive unit with an externally ventilated three-phase current generator, safety clutch and torque measuring flange.
- Truck gear box (test specimen) with oil conditioning device. The gear is flanged to a test specimen console. The test specimen is connected by jointed shafts with length compensation.
- Load unit, consisting of an externally ventilated three-phase current generator and a water-cooled planetary adapter gear box with transmissions 1:1 and 1:3.
The speed and torque are measured directly on the test specimen by digital shaft encoders and a torque measuring flange.
The following safety devices are provided to protect the test rig and the test specimen: total speed monitoring through the control and vibration monitoring of the test specimen and emergency bearing for the jointed shafts and slip clutches.
The speed and torque are measured directly on the test specimen by digital shaft encoders and a torque measuring flange.
The gear shift is executed by a switching robot. Selection and switching paths are operated by two servo motors.
A compressed air cylinder operates the clutch providing it is part of the test rig.
A manual terminal with user guidance and teach-in functions allows fast adaptation to new test specimens.
The following safety devices are provided to protect the test rig and the test specimen: differential speed monitoring through the control and vibration monitoring of the test specimen and emergency bearing for the jointed shafts and slip clutches.
The performance of the test rig is driven in a circle for the two three-phase current drives via a common DC intermediate circuit of the SIMOVERT converter. This gives an approximately halved connection rating. The reactive power requirement of this design is negligibly small in comparison to a solution with DC drives.
Technical Data
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