Test device, test method, control unit and computer program product for a gear mechanism

Abstract

The invention relates to a testing device (10) for gear mechanisms (20, 30), comprising a drive unit (12) and an output unit (14) which are connected to one another via first and second gear mechanisms (20, 30). According to the invention, at least the first gear mechanism (20) is designed to be adjustably tilted in order to test the first and second gear mechanisms (20, 30) at least partially simultaneously. The invention also relates to a method for testing gear mechanisms (20, 30) at least partially simultaneously, which can be implemented on a corresponding testing device (10). The invention likewise relates to a corresponding computer program product (60) for carrying out the method (100) on such a testing device (10).

Description

Technical Field

[0001] This invention relates to a testing apparatus for gearboxes and a corresponding testing method. The invention also relates to a control unit configured to execute the testing method according to the invention on such a testing apparatus. Furthermore, the invention relates to a computer program product capable of being stored on and executed on the control unit for the purpose of executing the testing method. Background Technology

[0002] Clemson University website

[0003] The website https: / / www.clemson.edu / cecas / departments / charleston / energy / wind-turbine-test-beds.html discloses a datasheet for a test bench for a wind turbine nacelle or its drivetrain. The test bench is designed for maximum drive power of 7.5MW and 15MW. Each test bench has at least one drive motor connected via a high-speed shaft to an accompanying gearbox. A low-speed shaft is formed from the accompanying gearbox, driving the rotor of the wind turbine nacelle under test. The rotor of the wind turbine nacelle is connected by means of a generally annular load application unit suitable for simulating the operating conditions of a wind turbine.

[0004] Web page

[0005] The website https: / / w3.windmesse.de / windenergie / pm / 27102-iwes-enercon-test-prufstand-go ndel-anlegenzertifizierung showcases a wind turbine test stand at the Fraunhofer Institute for Wind Energy Systems (IWES) in Bremerhaven. The test stand features a slowly rotating direct drive that powers the wind turbine under test.

[0006] Patent publication DE 10 2010 053 808 A1 discloses a wind turbine gearbox test bench capable of mounting two gearboxes. The gearboxes are driven by a drive unit connected to a load unit via torsion bars. The load unit is connected to two torsion bars that can clamp each other.

[0007] Patent document EP 2 574 778 B1 discloses a test apparatus for a gearbox and an electromechanical energy converter, wherein the gearbox to be tested is mounted in a gear system. Drive power is supplied to the gearbox to be tested via multiple electric motors and is also directed to the electromechanical energy converter.

[0008] DE 10 2012 021 007 A1 discloses a test apparatus for a wind turbine gearbox. Two gearboxes are interconnected via a centrally rotatable shaft. Each gearbox is connected to a gearbox bracket, which is grounded. The two gearboxes can undergo rotational changes in their position relative to each other. This is to change the relative position of the two gear shafts to avoid interference, vibration, and noise.

[0009] High-power gearboxes are used in various applications, and their development or certification processes require testing of the corresponding gearboxes. Therefore, there is a need for a gearbox testing apparatus that allows for rapid test runs, provides high flexibility, and can be manufactured in a simple manner. The object of this invention is to provide a possibility for testing gearboxes, which offers improvements in at least one of the aspects outlined. Summary of the Invention

[0010] This objective is achieved by a testing apparatus for a gearbox according to the invention, the apparatus comprising a drive unit and an output unit. The drive unit provides mechanical drive power, which drives the gearbox under test. For this purpose, the drive unit can be, for example, an electric motor. The output unit is configured to receive the mechanical drive power transmitted from the gearbox. For this purpose, the output unit can be, for example, a generator or a brake. The drive unit and the output unit are connected together via a first gearbox and a second gearbox, which will be tested by means of the testing apparatus. Mechanical drive power is transmitted from the drive unit to the output unit via the connection of the first and second gearboxes. By adjusting the mechanical drive power, the speeds occurring in the first and second gearboxes during test operation can be specified. According to the invention, at least the first gearbox is configured to be adjustablely tiltable and / or displaceable. The testing apparatus is therefore configured to adjustably tilt and / or displace at least the first gearbox when it is connected to the testing apparatus as intended. This tilting occurs about at least one spatial axis, which can be oriented perpendicular to or coincide with the main axis of rotation of the first gearbox. The displacement occurs translationally along at least one spatial axis. The tilting and / or displacement also induces a mechanical reaction at the second gearbox. This allows for the testing of both the first and second gearboxes, at least partially simultaneously.

[0011] Testing the first and second gearboxes at least partially simultaneously makes accelerated testing operations possible. Specifically, the first and second gearboxes can be of different types, meaning they are structurally different or not interchangeable. Different types should thus be understood as referring to first and second gearboxes having different components in certain places. They could be, for example, gearboxes with different bearings but identical structures. Similarly, gearboxes whose components are manufactured using different processes but otherwise have the same structure can also be tested at least partially simultaneously. This allows for testing different types, models, or variations of gearboxes in a common test run, thereby reducing, for example, the number of test runs required by the testing procedure. The required number of test runs can thus be roughly halved, allowing for generally economical testing operations.

[0012] In the claimed test apparatus, the tilting and / or displacement of the first gearbox between the first and second gearboxes generates a mechanical reaction. This mechanical reaction includes reaction force and / or reaction torque. This allows for the simulation of real gearbox operation, where the mechanical drive power deviates from an idealized axis of rotation. Particularly in the case of gearboxes used in wind turbines, this allows for the simulation of real operating conditions with varying wind conditions. The mechanical reaction, including reaction force and / or reaction torque, can therefore be purposefully specified and suitably incorporated as part of a test run performed with the test apparatus, as an operating condition specification. Overall, this allows for the specification of a wide range of procedures for testing gearboxes, such as those specified by the user, algorithms, or tables. In particular, it allows for the linking of measurement data obtained for the first and second gearboxes during the test run using simple timestamps. Such a link ensures the comparability of the two gearboxes under corresponding operating conditions in a simple manner. This also reduces the overall time required for the test procedure.

[0013] Furthermore, the second gearbox is also configured to be tiltable and / or displaceable. The tiltability or displaceability of the second gearbox thus corresponds to the tiltability of the first gearbox. Specifically, similar to the tiltability and / or displaceability of the first gearbox, the testing apparatus is also configured to adjustably tilt and / or displace the second gearbox. The tiltability and / or displaceability of the second gearbox allows for the induction of a wider range of stresses during test runs, and therefore a wider range of reaction forces and / or reaction torques. Similarly, the first and second gearboxes can tilt and / or displace simultaneously, thus allowing for the distribution of the desired offset among multiple tilting and / or displacement movements. This further increases the flexibility of the claimed testing apparatus.

[0014] The claimed test apparatus has at least one actuator configured to tilt and / or displace at least a first gearbox. For this purpose, for example, the actuator can be fixedly connected to the surrounding area. Alternatively or additionally, the actuator can also be arranged between the first and second gearboxes and / or can be in the form of a rotary actuator. In particular, the actuator can be in the form of a hydraulic cylinder, a servo motor, and / or a spindle drive. Actuators, especially hydraulic cylinders, have different structural forms that provide high actuation force and simultaneously high actuation accuracy. Similarly, the reached actuation position of the actuator can be precisely maintained. In particular, tilting and / or displacement can be precisely performed during test runs, which in turn produces accurate measurement data. Alternatively or additionally, the first gearbox can also be tilted and / or displaced via multiple actuators, thereby achieving the advantages outlined to a greater extent. Further alternatively or additionally, the second gearbox can also be configured to be tiltable and / or displaceable via at least one actuator. In this way, the advantages of precise test run execution described above are also realized to a greater extent. Actuators, such as hydraulic cylinders, can also be available in various sizes. Technically complex annular or crown-shaped load application units are not required in the protected test unit. Maintenance of such actuators can be performed in a similarly simple manner, allowing for particularly cost-effective maintenance. Overall, the protected solution thus offers exceptionally high economic efficiency.

[0015] Furthermore, in the claimed test apparatus, the first gearbox is arranged on a tiltable support frame. Such a support frame can be arranged, for example, on a hinged support and / or at least one actuator. The spatial position of the support frame can be changed by actuation of at least one actuator. The first gearbox can be secured to a test base on the support frame. Thus, standardized test setups exist for various types of gearboxes, where, in a simple manner, by setting the desired translational displacement and / or tilt angle, the reaction force and / or reaction torque can also be set via substantially the same control commands and standardized test runs. Alternatively or additionally, a second gearbox can also be arranged on such a support frame. The use of a support frame provides an overall standardized test setup in the claimed test apparatus, applicable to a large number of different types of gearboxes, and allows for simplified execution of test runs.

[0016] In another embodiment of the claimed test apparatus, the first gearbox and the second gearbox are connected together in opposite transmission directions. This arrangement is also known as a back-to-back arrangement. As a result, when observed along the flow of mechanical drive power, the current speed in the gearbox first increases and then decreases. Alternatively, the first and second gearboxes can also be arranged in opposite directions regarding the increase and decrease. Mechanical drive power is thus supplied to the output unit, allowing for mechanical losses, and the speed of the output unit may be similar to, the same as, or different from the speed at the output of the drive unit. The drive unit and the output unit, such as an electric motor and a generator, can therefore be configured, for example, as structurally identical electromechanical machines operating in opposite directions. This simplifies the maintenance of the claimed test apparatus, which in turn allows for particularly economical operation. Furthermore, such an arrangement allows for substantially mirror-reversible reaction forces and / or reaction torques when the first and second gearboxes tilt and / or shift. This ensures the comparability of measurement data from the first and second gearboxes during test runs. Therefore, it ensures that the first and second gearboxes can be optimally fully loaded during test runs. Overall, the advantages of the claimed solution are thus realized to a greater extent.

[0017] The at least one actuator can be further secured to the underlying floor. This ensures a stable connection with the surrounding area, which in turn allows for permanently accurate test runs. Specifically, the at least one actuator can be arranged below at least the first gearbox. For example, multiple actuators can be arranged on a foundation housed below the floor plane. The floor plane should be understood here as the ground level of the surrounding area, such as the hallway floor. Therefore, the foundation can be located substantially within a cellar-like cavity. The at least one actuator is thus arranged at least partially below the floor plane. The actuator can therefore be positioned on a reduced foundation area, which in turn allows for reduced structural costs. Furthermore, the test setup has reduced vertical dimensions. Therefore, the test setup can be installed in a lower hallway, which also allows for lower crane rails in the hallway. The protected test setup also provides improved accessibility, making maintenance easier. Similarly, the foundation below the floor plane, together with the walls, can serve as a channel. Such a channel prevents hydraulic fluid from entering the surrounding area, for example, in the event of a leak. Therefore, the required protective testing equipment should be space-saving, cost-effective to manufacture and maintain, and provide a high level of protection against environmental damage.

[0018] According to another embodiment of the claimed test apparatus, the first gearbox or the second gearbox can be directly connected to the drive unit or the output unit in a torque-transmitting manner. In such a direct connection, the mechanical drive power generated by the drive unit is supplied to the first or second gearbox, without any change in the current speed or torque. Accordingly, the mechanical drive power does not change further in terms of speed or torque between the gearbox and the output unit. Therefore, the claimed test apparatus does not require an accompanying gearbox or a so-called direct drive unit. In this way, the aforementioned advantages of the claimed test apparatus are further enhanced.

[0019] Furthermore, the first and / or second gearboxes can be in the form of wind turbine gearboxes. During the prototype testing or certification of wind turbine gearboxes, different wind conditions, such as changes in wind direction and force, will be tested during test runs. To simulate such wind conditions, mechanical drive power is introduced into the gearbox in a manner deviating from the idealized main axis of rotation. For example, the mechanical drive power will be subjected to a radial lateral force acting on the input shaft of the respective gearbox. Such a radial lateral force may occur on the rotor of the wind turbine due to wind loads, and then act on the rotor shaft connected to the input shaft of the gearbox. The claimed test apparatus provides a simple and economical possibility for generating corresponding reaction forces and / or reaction torques simulating such wind conditions by tilting and / or moving at least the first gearbox. The technical advantages of the claimed test apparatus can be realized to a certain extent when using this apparatus to test wind turbine gearboxes. Similarly, the claimed test apparatus can simulate a wide range of operating conditions for gearboxes used in industrial applications. By testing both gearboxes at least partially simultaneously, it is possible to quickly determine which gearbox model is best suited for the new intended use.

[0020] Furthermore, a control unit configured to tilt at least the first gearbox can be associated with the claimed test apparatus. The control unit is adapted to output control commands to components of the test apparatus, such as actuators, and thus generate reaction forces and / or reaction torques, by which operating condition specifications are implemented at least at the first gearbox. This allows for the simulation, for example, of varying wind conditions. In particular, reaction forces and / or reaction torques relative to multiple spatial axes can therefore be specified in a simple manner. The control unit can be additionally configured to control other components of the test apparatus, for example, by specifying the speed of a drive unit. Similarly, other parameters that may be relevant to the test run, such as pressure, temperature, or speed, can be set by means of the control unit. The control unit can be directly associated with the test apparatus, for example, as an internal control unit. Alternatively, the control unit can also be in the form of a higher-level control unit coupled to the test apparatus via a data link. Further alternatively, the control unit can also be in the form of a combination of an internal control unit and a higher-level control unit. The control unit allows the user to set operating condition specifications for the test run in a simple manner, for example, through user input, algorithms, or by means of tables, which reproduce the desired test run. Such a control unit therefore provides improved ease of use and high flexibility during operation for the required test equipment.

[0021] Furthermore, the test apparatus to be protected is provided with a central bearing, by means of which the first gearbox and the second gearbox are connected together. For this purpose, the first and second gearboxes are arranged on opposite sides of the central bearing and releasably connected thereto. The central bearing is configured to absorb radial forces acting on at least one shaft connecting the first and second gearboxes in a torque-transmitting manner. The central bearing can be directly connected to the surrounding area, i.e., the subfloor or foundation. Alternatively, the central bearing can also be connected to the surrounding area via an actuator. The central bearing serves to introduce the absorbed radial forces into the surrounding area. Alternatively, test forces can also be applied to the central bearing by the actuator, and thus also to the first and second gearboxes. This allows for the simulation of complex dynamic operating conditions, such as changing wind conditions, in various ways.

[0022] The objective is also achieved by a method for testing gearboxes according to the invention. The method according to the invention includes a first step in which a first gearbox and a second gearbox are arranged in a testing apparatus as described above. In a subsequent second step, a drive unit associated with the testing apparatus is activated. By means of the drive unit, mechanical drive power is provided to the first and second gearboxes, thereby establishing the gearbox operation to be determined within the test range. Accordingly, a load torque is provided by an output unit. In a third step of the method, at least the first gearbox is tilted and / or displaced adjustably. This induces a reaction force and / or reaction torque between the first and second gearboxes. According to the invention, the reaction force and / or reaction torque corresponds to a test force or test torque. In the presence of a central bearing, it also exists in the form of a radial force. The test force or test torque constitutes part of an operating condition specification that forms part of the expected test run. This allows for the simulation of varying wind conditions, for example, at a wind turbine, and thus the simulation of varying operating conditions of a wind turbine gearbox. After at least the first gearbox is tilted and / or shifted in an adjustable manner, measurement data describing the load state of the gearbox to be determined can be recorded at the first gearbox and / or the second gearbox by means of at least one sensor.

[0023] In one embodiment of the claimed method, the testing of the first gearbox and the second gearbox can be performed at least partially simultaneously. The mechanical reaction, including the reaction force and / or reaction torque, is substantially the same (mirror-reversed) for both the first and second gearboxes, thus ensuring that the same operating conditions exist at least partially simultaneously for both gearboxes in the same test run. As a result, measurement data regarding the first gearbox can be directly compared with measurement data regarding the second gearbox, for example, by means of timestamps. Specifically, the first and second gearboxes can be of different types. The claimed method improves efficiency because it is now possible to test two different types of gearboxes simultaneously compared to known solutions. Alternatively, two identical gearboxes can also be tested simultaneously. By using two identical gearboxes, at least two corresponding measurement data items exist for each state, making the results of the test run more meaningful through their statistical evaluation, such as by averaging. This reduces the duration of testing procedures, such as certification tests.

[0024] The described test apparatus allows for the rapid and economical execution of the required protection methods in a particularly simple, low-maintenance, and accurate manner.

[0025] The aforementioned objectives are also achieved by a control unit according to the invention. The control unit includes a memory and a computer unit, and is adapted to receive user input and output control commands to at least one actuator of the test apparatus. The control unit can be directly associated with the test apparatus as an internal control unit, or it can be a higher-level control unit coupled to the test apparatus via a data link. The internal control unit can be, for example, a programmable logic controller, or PLC for short. The higher-level control unit can be, for example, a host computer, a network server, a handheld device, or a computer cloud. Furthermore, the control unit can also be a combination of an internal control unit and a higher-level control unit. The control unit according to the invention is configured to execute at least one method according to the above embodiments. For this purpose, a computer program product can be stored in the control unit in an executable manner. The control unit according to the invention can also be connected to a test apparatus according to one of the above embodiments.

[0026] The stated objective is also achieved by a computer program product according to the invention. The computer program product is configured to specify and set test forces and / or test torques for testing the gearbox during test runs. The computer program product is configured to output control commands to at least one actuator forming part of the test apparatus. The computer program product can be configured as software, in chip form (i.e., hardwired), or as an FPGA circuit, or a combination thereof. Furthermore, the computer program product can be in the form of a single program or a system of at least two subroutines that can execute on separate hardware and communicate with each other to implement the operation of the computer program product. According to the invention, the computer program product is configured to execute on a control unit according to the invention. By means of the computer program product, in conjunction with the control unit, a test apparatus according to one of the above embodiments can be operated or one of the above methods can be implemented. The computer program product according to the invention provides the possibility of testing two gearboxes together in a simple manner and provides a high degree of configurability. In particular, it is possible to set user-inputted operating condition specifications, which can be automatically converted by the computer program product into corresponding reaction forces and / or reaction torques. Therefore, the claimed test apparatus can also be controlled by the claimed computer program product during operation. Furthermore, the computer program product can be configured to store and evaluate measurement data received from at least one sensor mounted on the first or second gearbox. In particular, simulated images of the first and / or second gearbox and / or wind turbines and / or industrial applications can also be stored in the computer program product according to the invention. Such simulated images are also referred to as digital twins. The operation and use of the corresponding testing equipment are thus simplified, accelerating the testing process. Attached Figure Description

[0027] The invention will be described below with reference to the accompanying drawings of various embodiments. The features of the drawings can thus be readily combined with each other. These drawings should be read in a complementary manner, provided that the same reference numerals have the same technical meaning. Specifically:

[0028] Figure 1 A cross-sectional view of a first embodiment of the claimed test apparatus;

[0029] Figure 2 A partial sectional perspective view of a second embodiment of the claimed test apparatus;

[0030] Figure 3 A perspective view of a third embodiment of the claimed testing apparatus;

[0031] Figure 4 The implementation of an embodiment of the claimed test method is illustrated schematically;

[0032] Figure 5 Details of a fourth embodiment of the claimed test apparatus are shown schematically. Detailed Implementation

[0033] Figure 1A first embodiment of the claimed test apparatus 10 is schematically shown in cross-sectional view. For better overview, P is depicted as a comparative standard. The test apparatus 10 includes a drive unit 12 in the form of an electric motor and an output unit 14 in the form of a generator. The drive unit 12 and the output unit 14 are each arranged on a base 21. A first gearbox 20 and a second gearbox 30, in the form of a wind turbine gearbox 47, are arranged between the drive unit 12 and the output unit 14. The first gearbox 20 and the second gearbox 30 are of different types and will be tested on the test apparatus 10. Mechanical drive power 25 can be provided by the drive unit 12 and transmitted to the output unit 14 by the first gearbox 20 and the second gearbox 30. The drive power 25 is generated about a rotational axis 15 of the first gearbox 20 and the second gearbox 30, which, in the case of the test apparatus 10, represents a spatial axis 35. The operation of the drive unit 12 can be assisted at least by means of power generation from the output unit 14 in the form of a generator. To transmit mechanical drive power 25, drive unit 12 is directly connected to the first gearbox 20 via power shaft 32 on its output side 29 in a torque-transmitting manner. Similarly, the second gearbox 30 is directly connected to the output unit 14 via power shaft 32 on its output side 29 in a torque-transmitting manner. The first gearbox 20 and the second gearbox 30 are connected together via a central bearing 34. The central bearing 34 is configured to connect the shafts of the first gearbox 20 and the second gearbox 30 in a torque-transmitting manner and to absorb radial forces relative to the main axis of rotation 15. The central bearing 34 is also connected to the surrounding area, i.e., the floor plane 16, via an actuator. Radial forces can be introduced into the first gearbox 20 and the second gearbox 30 by means of the actuator 22. Along... Figure 1 The flow of mechanical drive power 25, indicated by the middle arrow, decelerates in the first gearbox 20 but accelerates in the second gearbox 20. The first gearbox 20 and the second gearbox 30 are each connected to the connecting flange 34 via their drive sides 26, and thus in opposite transmission directions, i.e., in the direction of speed change.

[0034] The first gearbox 20 and the second gearbox 30 are each fastened to a test base 24, each test base 24 being connected to a support frame 18, which is located approximately at the ground plane on the floor plane 16. The support frame 18 is configured to be tiltable and / or displaceable, thereby enabling the intentional induction of mechanical reaction in the region of the central bearing 34. For this purpose, each support frame 18 is fastened to an actuator 22 in the form of a hydraulic cylinder. Each actuator 22 is configured to apply an actuator force 33 and thus cause a tilt 27 and / or displacement 36 of the first gearbox 20 and / or the second gearbox 30. Such tilting 27 and / or displacement 36 can occur about a plurality of spatial axes 35, such as... Figure 1As shown. Depending on the orientation of tilt 27 or displacement 36, mechanical reaction 40 includes reaction forces 42 oriented in different spatial directions in the region of the central bearing 34. Accordingly, mechanical reaction 40 also includes reaction torque 44, which has a different orientation corresponding to reaction force 42. The actuation of actuator 22 is adjustable so that tilt 27 and / or displacement 36 of the first gearbox 20 and / or the second gearbox 30 can be intentionally induced. The mechanical reaction 40 thus induced corresponds to the desired operating state of the first gearbox 20 and the second gearbox 30, in which they will be tested. Therefore, reaction force 42 and / or reaction torque 44 exist in the first gearbox 20 and the second gearbox 30. In particular, tilt 27 and / or displacement 36 of the first gearbox 20 and / or the second gearbox 30 results in corresponding stresses that are mirror-reversed in the two gearboxes 20, 30. The mechanical reaction 40, namely the corresponding reaction force 42 and reaction torque 44, can be detected by sensors 45 arranged in each of the first gearbox 20 and the second gearbox 30. For this purpose, the sensors 45 are installed at measuring points 51 in the first gearbox 20 and the second gearbox 30. Therefore, the test results obtained for the first gearbox 20 and the second gearbox 30 can be directly compared with each other.

[0035] In the test apparatus 10, actuators 22 are arranged on a foundation 17 located below the floor plane 16. The foundation 17 serves as the base floor 19 and is located below a support frame 18 with test bases 24 for gearboxes 20, 30. The actuators 22 are thus positioned essentially within a cellar-like cavity. The actuators 22 can be positioned close to each other, thereby reducing the size of the foundation 17. A fully loadable foundation 17 and a fully loadable base 21 are complex and costly. Compared to solutions known in the prior art, the test apparatus 10 requires a smaller foundation 17 and base 21, thus enabling production with reduced structural costs.

[0036] Figure 2 A second embodiment of the claimed test apparatus 10 is schematically shown in a partial sectional oblique view. For a better overview, in Figure 2The image also depicts a person P standing on the floor plane 16. The testing device 10 includes a drive unit 12 and an output unit 14, which are connected together via a first gearbox 20 and a second gearbox 30 in a torque-transmitting manner. Gearboxes 20 and 30 are in the form of wind turbine gearboxes 47 and are of different types. The first gearbox 20 and the second gearbox 30 will be tested at least partially simultaneously in the testing device 10. The drive unit 12 is arranged on a base 21 and is in the form of an electric motor, by means of which mechanical drive power 25 is provided. The mechanical drive power 25 (its flow direction is indicated by arrow 25) is transmitted directly to the output side 29 of the first gearbox 20 via a power shaft 32. The mechanical drive power 25 has a torque oriented around the gearboxes 20 and 30, in the case of the testing device 10, corresponding to the rotational axis 15 of the spatial axis 35. The first gearbox 20 and the second gearbox 30 are connected to a central bearing 34 via their respective drive sides 26. Acceleration occurs in the first gearbox 20, and deceleration occurs in the second gearbox 30. Along the flow direction of the mechanical drive power 25, the first gearbox 20 and the second gearbox 30 are thus connected together in opposite transmission directions. This arrangement is also referred to as a back-to-back arrangement. Accordingly, the second gearbox 30 is also directly connected on its output side 29 to an output unit 14 in the form of a generator via a power shaft 32. The drive unit 12 is capable of operating at least partially by the electrical energy obtained from the output unit 14. The output unit 14, corresponding to the drive unit 12, is also located on the base 21.

[0037] Gearboxes 20 and 30 are fastened to test bases 24, each test base 24 being mounted on a support frame 18. The support frame 18 is movably housed on a plurality of actuators 22 and supports 28. The actuators 22, in the form of hydraulic cylinders, are adapted to apply an actuator force 33, by means of which the support frame 18 can tilt and / or shift. The actuators 22 are arranged on a base frame 39 serving as a bottom floor 19 for the actuators 22. Thus, tilting 27 and / or shifting 36 of the first gearbox 20 and / or the second gearbox 30 about or along a spatial axis 35 can be achieved by the corresponding actuation of the actuators 22. Thus, mechanical reaction 40 is correspondingly generated in the first gearbox 20 and the second gearbox 30 in a mirror-reversed manner, which in each case includes a reaction force 42 and a reaction torque 44. The reaction forces 42 and reaction torques 44 in the first gearbox 20 and the second gearbox 30 are therefore substantially equal simultaneously in a mirror-reversed manner. Thus, the first and second gearboxes are simultaneously subjected to the same mechanical stresses. This simultaneous occurrence of corresponding states allows for direct comparison of the test results of the first gearbox with those of the second gearbox. For this purpose, the test apparatus as a whole and each of the gearboxes 20, 30 is equipped with a sensor 45, which is arranged at a measurement point 51 (not shown in more detail) in the respective gearbox 20, 30. The sensor 45 is configured to transmit measurement data 53 to a control unit 50. The control unit 50 includes an internal control unit 52, which is directly associated with the test apparatus 10. The control unit 50 is also configured to output control commands 55 to at least one actuator 22. The control unit 50 also includes a higher-level control unit 54, which is connected to the internal control unit 52 via a data link 56. The higher-level control unit 54 can be in the form of a computer cloud or a mainframe computer, for example, cooperating with the internal control unit 52 to perform test operations. The internal control unit 52 and the higher-level control unit 54 each have a memory for storing and executing a computer program product 60, through which the test apparatus 10 can be operated. With the help of the computer program product 60, control commands 55 for the actuator 22 can be specified and / or measurement data 53 from the sensor 45 can be stored and / or processed.

[0038] Figure 3 A third embodiment of the claimed test apparatus 10 is schematically shown. For comparative purposes, Figure 3The image also shows a person, P. The test apparatus 10 includes a drive unit 12 and an output unit 14. Mechanical drive power 25 is provided by the drive unit 12 (in the form of an electric motor) and supplied to the first gearbox 20 via a power shaft 32. The first gearbox 20 is connected to the second gearbox 30 via a central bearing 34, and via the second gearbox 30, the mechanical drive power 25 is directly supplied to the output unit 14 (in the form of a generator) via the power shaft 32. The central bearing 34 is connected to the floor plane 16 via at least one actuator 22 or via a passive connection. A radial force relative to the rotational axis 15 can thus be applied to the first gearbox 20 and the second gearbox 30 at the central bearing 36. Both the first gearbox 20 and the second gearbox 30 are in the form of a wind turbine gearbox 47. In the test apparatus 10, the mechanical drive power 25 is transmitted along the rotational axis 15 of the gearboxes 20, 30 in the direction of the depicted arrow; in the test apparatus 10, the rotational axis 15 is interpreted as a spatial axis 35. Drive unit 12 and output unit 14 are each positioned on base 21, which stands upright on floor plane 16. Gearboxes 20 and 30, arranged between them, are each secured in test base 24, which is tiltable and displaceable along or about multiple spatial axes 35. Each test base 24 is fixedly connected to a support frame 18, which is tiltable together with the test base 24 about a hinge joint 38. The tilting 27 and / or displacement 36 of the first gearbox 20 and / or the second gearbox 30 can be achieved via actuator 22, which is connected to the test base 24 of the first gearbox 20 and the second gearbox 30. The actuator 22 is in the form of a hydraulic cylinder, and each is adapted to apply an actuator force 33. Mechanical reaction 40, including reaction force 42 and reaction torque 44, can be induced in the region of the central bearing 34 in the first gearbox 20 and / or the second gearbox 30 by tilting 27 and / or shifting 36. Mechanical reaction 40 is also determined by the radial force applied via the central bearing 36. The reaction force 42 and reaction torque 44 in the first gearbox 20 and the second gearbox 30 correspond in a mirror-reversed manner. Mechanical reaction 40 can therefore be intentionally positioned in the two gearboxes 20, 30, and the desired operating state of the gearboxes 20, 30 can thus be simulated during test runs. The test superstructure including the gearboxes 20, 30 is equipped with a sensor 45 located at a measurement point 51 (not shown in more detail) in or on the gearboxes 20, 30. Measurement data 53 that can be received by the control unit 50 can be generated by means of the sensor 45. The control unit 50 includes an internal control unit 52 directly associated with the test apparatus 10. The control unit 50 has a memory and is equipped with a computer program product 60, which is configured to store and / or process measurement data 53 from the sensor 45.The computer program product 60 is also configured to output control commands 55 for actuating the actuator 22. The first gearbox 20 and the second gearbox 30 can thus be tested at least partially simultaneously, and the simultaneously generated measurement data 53 can be directly compared with each other. Overall, this allows for particularly rapid and efficient direct comparison of gearboxes 20 and 30 during test runs.

[0039] Figure 4 An embodiment of the claimed method 100 for testing gearboxes 20, 30 using test apparatus 10 is illustrated schematically. Figure 4 Assuming that steps 110 and 120 have been performed, in which gearboxes 20 and 30 are installed in test apparatus 10 and test apparatus 10 is activated. In the first figure 70, the execution of test run 75 is depicted along the horizontal time axis 72. The first figure 70 also has a vertical numerical axis 74. During test run 75, the mechanical drive power 25 used to drive gearboxes 20 and 30 remains constant. In the second method step 120, a steady-state operation 48 is established, where gearboxes 20 and 30 are aligned, that is, their main axes of rotation 15 are aligned. Therefore, for the first gearbox 20 and / or the second gearbox 30 according to the first figure 70, there is a tilt 27 with a tilt angle 37 of zero degrees. Simultaneously, mechanical reaction 40 occurs at the first gearbox 20 and the second gearbox 30, as shown on the numerical axis 40 in the second figure 71. Figure 4 The embodiments assume that only the following exist: Figures 1 to 3 The tilt 27 shown causes mechanical reaction 40, but no displacement 36. Mechanical reaction 40 includes at least one reaction force 42 and at least one reaction torque 44, which are substantially constant during steady-state operation 48. The at least one reaction force 42 and the at least one reaction torque 44 are obtained substantially as supporting reactions of gearboxes 20, 30 in their respective test bases 24.

[0040] In the third step 130, following the steady-state operation 48 in the second step 120, there is a transition operation 49, in which at least the tilt angle 37 increases. In the third step 130, at least one actuator 22 of the test device 10 is actuated via the control unit 50, thereby causing a tilt 27 of the first gearbox 20 and / or the second gearbox 30. As a result of this tilt 27, the at least one reaction torque 44 and the at least one reaction force 42 increase and reach substantially constant values ​​in the fourth step 140. In the third step 130, as a result of the tilt 27, the desired operating state to be measured in the test run is achieved. In the third step 130, a measurement operation 58 is performed, in which measurement data 53 is generated by means of a sensor 45 mounted on a measurement point 51 in the gearboxes 20, 30, the actuator 22, the test base 24, and / or the support frame 18. In the second figure 71, the measurement data 53 is shown as an example of the measurement point 41, which is transmitted to the control unit 50 of the test device 10. Each measurement point 41 has a defined position on the time axis 72 and is depicted as a timestamp 59. With the help of the timestamp 59, the measurement data 53 of the first gearbox 20 and the second gearbox 30, i.e., the operating state that existed at that time, can be directly compared with each other.

[0041] Following the fourth step 140 is a further transition operation 49, in which the tilt angle 37 is reduced. Therefore, the at least one reaction force 42 and the at least one reaction torque 44 appear to a reduced degree. This is followed by a further steady-state operation 48, which can also be used as a measurement operation 58. Multiple passes through individual or all of the summarized steps 110, 120, 130, 140 can be combined to form a test run 75 with increased complexity. The control unit 50 is adapted to specify the actuation of the actuator 22 and / or store and / or evaluate the measurement data 53 from the test run 75 by means of control commands 55.

[0042] Figure 5 Details of a fourth embodiment of the claimed test apparatus 10 are illustrated schematically. Figure 5One of two gearboxes 20, 30 to be tested using test apparatus 10 is shown. Gearboxes 20, 30 are in the form of planetary gearboxes 31, particularly wind turbine gearboxes 47. Sensors 45 are provided on the ring gear 67, planet carrier 68, and sun gear 69. Sensors 45 are configured to detect expansion, force, temperature, and / or vibration, and are respectively located at measurement points 51. Mechanical drive power 25 is provided via a drive shaft 32, which is connected to the sun gear 69 in a torque-transmitting manner. Gearboxes 20, 30 can also be connected to another gearbox (not shown) via a central bearing 34. Each sensor 45 is coupled to an internal control unit 52 to transmit measurement data 53, the internal control unit 52 forming part of a control unit 50. The internal control unit 52 is adapted to receive user input 62, by means of which a test run 75 for test apparatus 10 can be set in a computer program product 60, the computer program product 60 being stored in the control unit 50 in an executable manner. With the help of the computer program product 60, it is thus possible to perform, for example... Figure 4 The method 100 is described in the diagram. The internal control unit 52 and the computer program product 60 are also configured to output control commands 55 to at least one actuator 22, by means of which the actuator force 33 to be applied can be specified. This allows the desired test run 75 to be set.

[0043] Furthermore, the internal control unit 52 is coupled to a higher-level control unit 54 via a data link 56. The data link 56 is in the form of an internet connection 64, and the higher-level control unit 54 is in the form of a computer cloud 65. The so-called digital twin 66, i.e., a simulated image of at least one gearbox 20, 30, is stored in the computer cloud 65 associated with the test apparatus 10. A computer program product 60 is also stored on the higher-level control unit 54, which collaborates with the computer program product 60 in the internal control unit 52 via the data link 56 and, for example, implements... Figure 4 Method 100. The higher-level control unit 54 is also configured to receive user input 62, by means of which test run 75 is set. For example, test force 61 and / or test torque 63 implemented by reaction force 42 or reaction torque 44 at the respective gearboxes 20, 30 can be specified by user input 62.

Claims

1. A testing device (10) for gearboxes (20, 30), comprising: A first gearbox (20) in the form of a planetary gearbox and a second gearbox (30) in the form of a planetary gearbox, wherein the ring gear (67), planet carrier (68) and sun gear (69) of the first and second gearboxes (20, 30) are all equipped with sensors (45). The drive unit (12) and output unit (14) are connected together via the first and second gearboxes (20, 30), and the central bearing (34) connects the two gearboxes (20, 30) together. The first and second gearboxes (20, 30) are each fastened to a test base (24), and each test base (24) is connected to a support frame (18) located at the ground plane on the floor plane (16), and each support frame (18) is fastened to an actuator (22). In order to test the first and second gearboxes (20, 30) at least partially simultaneously, the actuator (22) applies an actuator force (33) to cause at least the first gearbox (20) to tilt (27) and / or shift (36) about a plurality of spatial axes (35) as a mechanical reaction (40). The mechanical reaction (40), which has a reaction force (42) and a reaction torque (44) in the region of the central bearing (34), is detected by the sensor (45).

2. The testing apparatus (10) according to claim 1, characterized in that, The first and second gearboxes (20, 30) are connected together in opposite transmission directions.

3. The testing apparatus (10) according to claim 1 or 2, characterized in that, At least one actuator (22) is fastened to the bottom floor (19).

4. The testing apparatus (10) according to claim 1 or 2, characterized in that, The actuator (22) is arranged below the floor plane (16).

5. The testing apparatus (10) according to claim 1 or 2, characterized in that, The first or second gearbox (20, 30) is directly connected to the drive unit (12) or the output unit (14) in a manner that transmits torque.

6. The testing apparatus (10) according to claim 1 or 2, characterized in that, The first and / or second gearboxes (20, 30) are in the form of wind turbine gearboxes (47).

7. The testing apparatus (10) according to claim 1 or 2, characterized in that, Associated with the test device (10) is a control unit (50) for setting the tilt (27) of at least the first gearbox (20).

8. A method (100) for testing gearboxes (20, 30), comprising the following steps: a) The test apparatus (10) according to any one of the preceding claims is provided with first and second gearboxes (20, 30); b) Activate the drive unit (12) of the test device (10). c) Adjustably tilt (27) and / or shift (36) at least the first gearbox (20, 30) to generate a reaction force (42) and / or a reaction torque (44) between the first and second gearboxes (20, 30). The reaction force (42) and / or reaction torque (44) correspond to the test force (61) or test torque (63) that forms part of the expected test run (75).

9. The method (100) according to claim 8, characterized in that, The tests on the first and second gearboxes (20, 30) were conducted at least partially simultaneously.

10. A control unit (50) for outputting actuation commands for at least one actuator (22) of a test apparatus (10), characterized in that, The control unit (50) is configured to perform the method (100) according to claim 8 or 9.

11. A computer program product (60) for establishing test forces (61) and / or test torques (63) used to test gearboxes (20, 30) during a test run (75), and outputting control commands (55) for at least one actuator (22) of a test apparatus (10), characterized in that, The computer program product (60) is configured to be stored on and executed on the control unit (50) according to claim 10.

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