Gearbox test run: ensuring reliability and performance

Key Testing Parameters for the WPU-12/TS1 Gearbox

During the test run, we carefully monitor and record multiple critical parameters

Oil Inlet and Outlet Temperature: monitoring these temperatures ensures the cooling system is functioning correctly, and that the gearbox is adequately lubricated.

Bearing Temperatures: Axial Thrust Bearing - Roller Bearings - Temperature control is crucial to prevent overheating and ensure smooth operation of the bearings, which are critical for load distribution and reducing friction.

Oil Flow, Distribution, and Pressure: proper oil flow and pressure are essential for maintaining lubrication and preventing metal-to-metal contact, reducing wear and tear.

Vibrations: measuring vibration levels helps identify any bearing problems, imbalance or misalignment in the gearbox components, which can lead to premature failure.

Input Speed: verifying that the input speed matches the design specifications ensures that the gearbox will operate efficiently when integrated with the motor.

Power Loss: calculating power loss helps in understanding the efficiency of the gearbox and identifying any areas of improvement in energy transmission.

Dynamic and Static Oil Film Thickness: this measurement is vital for evaluating the lubrication quality between moving parts (thrust pads and output disc) and preventing direct surface contact.

Run-Out of Connecting Flange: checking the run-out ensures the alignment and precision of the gearbox assembly, crucial for minimizing vibration and wear.

Run-Down Time: measuring how long the gearbox takes to come to a complete stop after shutdown helps assess the internal friction and condition of the components.

Test conditions for accuracy and consistency:

The gearbox undergoes a full-speed, no-load test for 2 hours to simulate real-world operating conditions.

Driven by a variable-speed electrical DC motor, we can precisely control and measure the gearbox's response to different speeds.

The test uses a workshop lube oil unit with ISO VG 220 VCI oil to ensure proper lubrication.

Lube oil pressure is maintained at a minimum of 2.8 bar (low pressure) and 10 bar (high pressure) to simulate various operating scenarios.

Oil flow rate is kept at 140 l/min under low pressure to ensure optimal lubrication throughout the system.