A gear box test bench

Abstract

This invention discloses a gearbox test bench, comprising a movable frame serving as the load-bearing base, with a rectangular cabinet structure; a control unit disposed on one side of the upper part of the movable frame, arranged along the length of the movable frame; a power unit installed on the upper part of the movable frame, located on one side of the control unit, and detachably connected to the top of the movable frame; a gearbox testing station disposed on the upper part of the movable frame, located on one side of the power unit; a loading unit installed on the upper part of the movable frame, located above the control unit, and detachably connected to the top of the movable frame; and a transmission assembly including a first transmission component and a second transmission component, one end of the first transmission component being connected to the output shaft of the power unit. This invention enables rapid fixing, efficient testing, and accurate data acquisition of gearboxes of various specifications, while improving the mobility and ease of maintenance of the equipment.

Description

Technical Field

[0001] This invention belongs to the technical field of gearbox performance testing equipment, specifically relating to a gearbox test bench. Background Technology

[0002] The gearbox is a core component of a mechanical transmission system, and its performance directly determines the overall operating efficiency and reliability of the machine. Therefore, gearbox performance verification must be completed using a dedicated testing bench before leaving the factory and during the research and development phase. Existing gearbox testing benches have the following technical shortcomings: Traditional test benches are mostly custom-designed: small test benches are only compatible with gearboxes of specific modules (0.5-2mm) and center distances (50-200mm), requiring disassembly and reassembly of tooling when changing test objects, with a single adjustment taking over 4 hours; large wind turbine gearbox test benches are incompatible with small industrial gearboxes, resulting in insufficient equipment utilization. Furthermore, the clamping mechanism of the test station is a rigid fixed structure, unable to accommodate gearboxes with different installation standards (such as flange-type and shaft-extension type), with clamping errors exceeding 0.1mm, directly leading to a decrease in the testing accuracy of core parameters such as torque and speed. The power unit, loading unit, and control unit of existing test benches are often scattered: the power unit is located at one end of the bench, the control unit is independently set up in the operating room, and the loading unit is located at the other end of the bench, with exposed pipe and cable lengths exceeding 5 meters. Operation requires switching between multiple areas, resulting in low testing efficiency; simultaneously, exposed pipes are susceptible to environmental vibration interference, leading to sensor signal distortion and high data acquisition errors.

[0003] Traditional cooling systems are designed only for the power unit. Loading units (such as magnetic powder brakes) are prone to overheating due to continuous loading, leading to large fluctuations in load accuracy. Furthermore, the lack of isolation between the cooling components and the testing area allows hot air to directly blow onto the gearbox testing station, increasing deviations in vibration, noise, and other test data. Existing test benches use fixed-length drive shafts. When the gearbox shaft pitch changes, different length drive shafts must be replaced, resulting in numerous spare parts and replacement times exceeding one hour. Additionally, the drive shaft interface only accommodates a single type of gearbox shaft end, making it incompatible with input / output shafts of different diameters and keyway sizes.

[0004] The aforementioned deficiencies mean that existing gearbox test benches cannot meet the high-efficiency and high-precision testing requirements of gearboxes of various specifications, and there is an urgent need to develop a modular, highly adaptable, and integrated gearbox test bench. Summary of the Invention

[0005] In view of the problems mentioned in the background technology above, the purpose of this invention is to provide a gearbox test bench that overcomes the defects of existing gearbox test benches, such as poor versatility, low integration, inconvenient mobility, weak heat dissipation coordination, and inflexible transmission connection. The invention provides a gearbox test bench that enables rapid fixing, efficient testing, and accurate data acquisition of gearboxes of various specifications, while improving the mobility and ease of operation and maintenance of the equipment.

[0006] To achieve the above-mentioned technical objectives, the technical solution adopted by the present invention is as follows: A gearbox test bench, comprising: The mobile platform, serving as the load-bearing base, has a rectangular cabinet structure. The control unit is located in the upper part of the movable platform and is arranged along the length of the movable platform. The power unit is installed on the upper part of the mobile platform, located on one side of the control unit, and is detachably connected to the top of the mobile platform; The gearbox testing station is located on the upper part of the mobile platform, on one side of the power unit; The loading unit is installed on the upper part of the mobile platform, located above the control unit, and is detachably connected to the top of the mobile platform. The transmission assembly includes a first transmission component and a second transmission component. One end of the first transmission component is coaxially connected to the output shaft of the power unit, and the other end is detachably connected to the input interface of the gearbox test station. One end of the second transmission component is detachably connected to the output interface of the gearbox test station, and the other end is coaxially connected to the input shaft of the loading unit. The heat dissipation system includes at least one heat dissipation module, which is arranged on top of the power unit. One end of the heat dissipation module is connected to the cooling medium storage cavity built into the mobile platform through a pipe, and the other end is connected to the gearbox test station. The control unit is electrically connected to the power unit, the loading unit, and the heat dissipation system, respectively.

[0007] Further restrictions also include: An operation panel is embedded in the side of the control unit facing the operator, and the operation panel is electrically connected to the control unit; The cabinet doors are located on the side of the cabinet of the movable platform, and there are at least two doors, which are rotatably connected to the cabinet of the movable platform via hinges; The platform casters are installed at the four corners of the bottom of the cabinet of the mobile platform and are fixedly connected to the bottom frame of the mobile platform.

[0008] Further specifying, the control unit includes: The outer shell has a rectangular box-shaped structure and is fixed to one side of the top of the movable platform; An internal control module, located inside the outer casing, includes a PLC controller, a frequency converter drive module, a data acquisition module, and a communication module; The display screen assembly is embedded in the end face of the housing facing the operator and is electrically connected to the data acquisition module; The PLC controller is electrically connected to the frequency converter drive module, the data acquisition module, and the communication module, respectively. The frequency converter drive module is electrically connected to the power unit, and the data acquisition module is electrically connected to the sensors of the power unit, the loading unit, and the gearbox test station.

[0009] Further specifying, the power unit includes: Variable frequency motor, as the power output source; A motor encoder, installed on the non-output shaft end of the variable frequency motor, is an incremental encoder and is electrically connected to the control unit. It is used to collect motor speed and direction data in real time.

[0010] Further specifying, the gearbox testing station is equipped with a sensor group, which includes a torque sensor, a vibration sensor, and a temperature sensor, and the torque sensor, vibration sensor, and temperature sensor are electrically connected to the data acquisition module.

[0011] Further specifying, the loading unit includes: The loading body is selected from one of a magnetic powder brake, an eddy current dynamometer, or a servo loading motor. A loading encoder is installed on the non-input shaft end of the loading body. It is an absolute encoder and is electrically connected to the data acquisition module of the control unit. It is used to acquire loading torque and speed data in real time. The loading body is electrically connected to the PLC controller of the control unit, and the loading parameters can be set through the operation panel.

[0012] Further specified, the heat dissipation module of the heat dissipation system includes an axial fan and heat dissipation fins, the spacing of the heat dissipation fins is not less than 5mm, the height is not less than 30mm, and the axial fan is fixed to one side of the heat dissipation fins.

[0013] Further specifying, the operation panel includes: The start button, stop button, and emergency stop button are all self-resetting buttons with LED indicator lights, located on the left side of the operation panel, and electrically connected to the PLC controller of the control unit. The adjustment knobs, including the speed adjustment knob and the load adjustment knob, are located in the middle area of ​​the operation panel and are electrically connected to the frequency conversion drive module and the load body of the control unit, respectively.

[0014] Furthermore, the operation panel also includes a status indicator light group, which includes a power indicator light, a running indicator light, and a fault indicator light. This group is located on the right side of the operation panel and is electrically connected to the PLC controller of the control unit.

[0015] Further specifying, the cabinet door includes: The first cabinet door is provided corresponding to the cooling medium storage chamber of the movable platform, and a liquid level observation window is provided on its inner side for observing the remaining amount of cooling medium. The second cabinet door is located adjacent to the first cabinet door. Inside the second cabinet door are spare parts storage compartments and cable storage compartments, which are used to store test fixtures, sensor spare parts and cables.

[0016] The beneficial effects of this invention are: This invention integrates the control unit, power unit, and loading unit into a mobile test bench, centralizing operation on the control panel and improving testing efficiency. Spare parts and cables are stored inside the mobile test bench, further reducing signal distortion and improving test data accuracy. Casters on the test bench allow for flexible movement of the equipment, eliminating the need for disassembly during relocation. The spare parts storage structure within the test bench cabinet standardizes spare parts management, reducing maintenance costs. A sensor array collects parameters such as torque, speed, vibration, and temperature; combined with the control unit's data processing capabilities, it enables multi-dimensional testing of transmission efficiency, fatigue life, and fault characteristics, meeting the full-scenario needs of gearbox R&D and factory testing. Attached Figure Description

[0017] The present invention can be further illustrated by the non-limiting embodiments given in the accompanying drawings; Figure 1 This is a schematic diagram of the structure of an embodiment of a gearbox test bench according to the present invention; Figure 2 This is a top view of an embodiment of a gearbox test bench according to the present invention; Figure 3 This is a front view of an embodiment of a gearbox test bench according to the present invention; Figure 4 This is a side view of an embodiment of a gearbox test bench according to the present invention.

[0018] The symbols of the main components are explained as follows: 1. Moving platform; 2. Control unit; 3. Power unit; 4. Gearbox test station; 5. Loading unit; 6. Cooling system; 7. Operation panel; 8. Platform cabinet door; 9. Platform casters; 10. Transmission assembly; 11. Axial flow fan; 12. Heat dissipation fins; 13. First cabinet door; 14. Second cabinet door. Detailed Implementation

[0019] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be further described below with reference to the accompanying drawings and embodiments. The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0020] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0021] Furthermore, the use of terms such as "first" and "second" in this invention is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0022] like Figure 1 As shown, a gearbox test bench of the present invention includes: The mobile platform 1, serving as the load-bearing base, has a rectangular cabinet structure; Control unit 2 is disposed on one side of the upper part of the movable platform 1 and arranged along the length of the movable platform 1; The power unit 3 is installed on the upper part of the mobile platform 1, located on one side of the control unit 2, and is detachably connected to the top of the mobile platform 1. The gearbox testing station 4 is located on the upper part of the mobile platform 1, on one side of the power unit 3; The loading unit 5 is installed on the upper part of the mobile platform 1, located above the control unit 2, and is detachably connected to the top of the mobile platform 1. The transmission assembly 10 includes a first transmission component and a second transmission component. One end of the first transmission component is coaxially connected to the output shaft of the power unit 3, and the other end is detachably connected to the input interface of the gearbox test station 4. One end of the second transmission component is detachably connected to the output interface of the gearbox test station 4, and the other end is coaxially connected to the input shaft of the loading unit 5. The heat dissipation system 6 includes at least one heat dissipation module, which is arranged on top of the power unit 3. One end of the heat dissipation module is connected to the cooling medium storage cavity built into the mobile platform 1 through a pipe, and the other end is connected to the gearbox test station 4. The control unit 2 is electrically connected to the power unit 3, the loading unit 5, and the heat dissipation system 6, respectively.

[0023] In practical applications of this embodiment, it also includes: The operation panel 7 is embedded in the end face of the control unit 2 facing the operator, and the operation panel 7 is electrically connected to the control unit 2; The cabinet doors 8 are located on the side of the cabinet of the movable platform 1, and there are at least two doors. They are rotatably connected to the cabinet of the movable platform 1 via hinges. The platform casters 9 are installed at the four corners of the bottom of the cabinet of the mobile platform 1 and are fixedly connected to the bottom frame of the mobile platform 1.

[0024] In the practical application of this embodiment, the control unit 2 includes: The outer shell has a rectangular box-shaped structure and is fixed to one side of the top of the movable platform 1; the outer shell is made of aluminum alloy and the wall thickness is preferably 3mm. An internal control module, located inside the outer casing, includes a PLC controller, a frequency converter drive module, a data acquisition module, and a communication module; the PLC controller is an S7-1200 model, the power adaptation range of the frequency converter drive module is 0.75kW to 75kW, and the sampling frequency of the data acquisition module is 1kHz. The display screen assembly is embedded in the end face of the housing facing the operator and is electrically connected to the data acquisition module; preferably, there are three displays, each with a size of 7 inches. The PLC controller is electrically connected to the frequency converter drive module, the data acquisition module, and the communication module, respectively. The frequency converter drive module is electrically connected to the power unit 3, and the data acquisition module is electrically connected to the sensors of the power unit 3, the loading unit 5, and the gearbox test station 4.

[0025] Specifically, the communication module supports RS485 and Ethernet communication protocols and can communicate with external terminal devices (such as host computers) via wired connection; the operation panel 7 is integrated into the end face of the housing facing the operator, located in the area below the display screen group, and the gap between it and the housing is less than 0.5mm.

[0026] In the practical application of this embodiment, the power unit 3 includes: The variable frequency motor serves as the power output source; specifically, the variable frequency motor model is YE3 series, with a power range of 0.75kW~75kW and a rated speed of 1500r / min; The motor encoder is installed on the non-output shaft end of the variable frequency motor. It is an incremental encoder and is electrically connected to the control unit 2. It is used to collect motor speed and direction data in real time.

[0027] In the practical application of this embodiment, a sensor group is provided on the gearbox testing station 4. The sensor group includes a torque sensor, a vibration sensor, and a temperature sensor, which are electrically connected to the data acquisition module. The torque sensor is a JN338 model with a measurement range of 0–500 N·m; the vibration sensor is a piezoelectric accelerometer with a measurement range of 0–50 g; and the temperature sensor is a PT100 resistance temperature detector (RTD) with its probe extending to the lubrication chamber of the gearbox under test, and a measurement range of -20℃ to 150℃. In the practical application of this embodiment, the loading unit 5 includes: The loading body is selected from one of a magnetic powder brake, an eddy current dynamometer, or a servo loading motor; wherein the torque range of the magnetic powder brake is 10 N·m to 500 N·m, the power range of the eddy current dynamometer is 1 kW to 75 kW, and the torque range of the servo loading motor is 5 N·m to 300 N·m. A loading encoder is installed on the non-input shaft end of the loading body. An absolute encoder is used. The data acquisition module of the control unit 2 is electrically connected to the encoder and is used to acquire loading torque and speed data in real time. The loading body is electrically connected to the PLC controller of the control unit 2, and the loading parameters can be set through the operation panel 7.

[0028] In the practical application of this embodiment, the heat dissipation module of the heat dissipation system 6 includes an axial fan 11 and heat dissipation fins 12. The spacing of the heat dissipation fins 12 is not less than 5mm and the height is not less than 30mm. The axial fan 11 is fixed to one side of the heat dissipation fins 12.

[0029] In the practical application of this embodiment, the operation panel 7 includes: The start button, stop button, and emergency stop button are all self-resetting buttons with LED indicator lights, located on the left side of the operation panel 7, and electrically connected to the PLC controller of the control unit 2; The adjustment knobs, including the speed adjustment knob and the load adjustment knob, are located in the middle area of ​​the operation panel 7 and are electrically connected to the frequency conversion drive module and the load body of the control unit 2, respectively.

[0030] In the practical application of this embodiment, the operation panel 7 also includes a status indicator group, which includes a power indicator, a running indicator, and a fault indicator. The status indicator group is located on the right side of the operation panel 7 and is electrically connected to the PLC controller of the control unit 2.

[0031] In the practical application of this embodiment, the cabinet door 8 includes: The first cabinet door 13 is provided corresponding to the cooling medium storage cavity of the movable platform 1, and a liquid level observation window is provided on its inner side for observing the remaining amount of cooling medium. The second cabinet door 14 is located adjacent to the first cabinet door 13. The second cabinet door 14 has a spare parts storage cavity and a cable storage cavity for storing test fixtures, sensor spare parts and cables.

[0032] The working principle of this embodiment is as follows: According to the specifications of the gearbox to be tested (center distance, shaft end size, power), adjust the positions of the power unit 3, gearbox test station 4, and loading unit 5 on the moving platform 1. Adjust the position of each unit by loosening / tightening the bolts to complete the fixation of the gearbox; open the platform cabinet door 8, add coolant to the cooling medium storage chamber, close the cabinet door and lock it.

[0033] The device is started by pressing the start button on the control panel 7. The variable frequency drive module of the control unit 2 drives the variable frequency motor of the power unit 3 to run. The power is transmitted to the input shaft of the gearbox under test through the first transmission component. At the same time, the PLC controller sends a load command to the loading unit 5. The loading body applies a simulated load to the output shaft of the gearbox through the second transmission component. The sensor group of the gearbox test station 4 collects torque, vibration and temperature data in real time. After being processed by the data acquisition module, the data is displayed on the display screen. The heat dissipation system 6 automatically adjusts the heat dissipation power according to the temperature data of the power unit 3 and the loading unit 5.

[0034] When the test is finished, stop the equipment by pressing the stop button on the operation panel 7. The PLC controller will then cut off the power supply to the loading unit 5 and the power unit 3 in sequence. After the gearbox has cooled down, loosen the clamping assembly and remove the gearbox. Open the bench cabinet door 8, clean the test fixture and store it in the spare parts storage cavity, and close the cabinet door to complete the test.

[0035] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A gearbox test bench, characterized in that, include: The mobile platform (1) serves as the load-bearing base and has a rectangular cabinet structure. The control unit (2) is located on one side of the upper part of the movable platform (1) and is arranged along the length of the movable platform (1); The power unit (3) is installed on the upper part of the mobile platform (1), located on one side of the control unit (2), and is detachably connected to the top of the mobile platform (1). The gearbox test station (4) is located on the upper part of the mobile platform (1) and on one side of the power unit (3); The loading unit (5) is installed on the upper part of the mobile platform (1), located on the upper side of the control unit (2), and is detachably connected to the top of the mobile platform (1). The transmission assembly (10) includes a first transmission component and a second transmission component. One end of the first transmission component is coaxially connected to the output shaft of the power unit (3), and the other end is detachably connected to the input interface of the gearbox test station (4). One end of the second transmission component is detachably connected to the output interface of the gearbox test station (4), and the other end is coaxially connected to the input shaft of the loading unit (5). The heat dissipation system (6) includes at least one heat dissipation module, which is arranged on top of the power unit (3). One end of the heat dissipation module is connected to the cooling medium storage cavity built into the mobile platform (1) through a pipe, and the other end is connected to the gearbox test station (4). The control unit (2) is electrically connected to the power unit (3), the loading unit (5), and the heat dissipation system (6), respectively.

2. The gearbox test bench according to claim 1, characterized in that, Also includes: The operation panel (7) is embedded in the side of the control unit (2) facing the operator, and the operation panel (7) is electrically connected to the control unit (2). The cabinet door (8) is located on the side of the cabinet of the mobile platform (1), and there are at least two doors. The doors are rotatably connected to the cabinet of the mobile platform (1) via hinges. The platform casters (9) are installed at the four corners of the bottom of the cabinet of the mobile platform (1) and are fixedly connected to the bottom frame of the mobile platform (1).

3. The gearbox test bench according to claim 1, characterized in that, The control unit (2) includes: The outer shell has a rectangular box-shaped structure and is fixed to one side of the top of the movable platform (1); An internal control module, located inside the outer casing, includes a PLC controller, a frequency converter drive module, a data acquisition module, and a communication module; The display screen assembly is embedded in the end face of the housing facing the operator and is electrically connected to the data acquisition module; The PLC controller is electrically connected to the frequency conversion drive module, the data acquisition module, and the communication module respectively. The frequency conversion drive module is electrically connected to the power unit (3). The data acquisition module is electrically connected to the sensors of the power unit (3), the loading unit (5), and the gearbox test station (4).

4. A gearbox test bench according to claim 1, characterized in that, The power unit (3) includes: Variable frequency motor, as the power output source; The motor encoder is located on the non-output shaft end of the variable frequency motor and is an incremental encoder. The control unit (2) is electrically connected to it and is used to collect motor speed and direction data in real time.

5. A gearbox test bench according to claim 3, characterized in that: The gearbox test station (4) is equipped with a sensor group, which includes a torque sensor, a vibration sensor and a temperature sensor. The torque sensor, vibration sensor and temperature sensor are electrically connected to the data acquisition module.

6. A gearbox test bench according to claim 3, characterized in that: The loading unit (5) includes: The loading body is selected from one of a magnetic powder brake, an eddy current dynamometer, or a servo loading motor. The loading encoder is set at the non-input shaft end of the loading body and is an absolute encoder. The data acquisition module of the control unit (2) is electrically connected to it and is used to collect loading torque and speed data in real time. The loading body is electrically connected to the PLC controller of the control unit (2), and the loading parameters can be set through the operation panel (7).

7. A gearbox test bench according to claim 1, characterized in that: The heat dissipation module of the heat dissipation system (6) includes an axial fan (11) and heat dissipation fins (12). The spacing of the heat dissipation fins (12) is not less than 5 mm and the height is not less than 30 mm. The axial fan (11) is fixed to one side of the heat dissipation fins (12).

8. A gearbox test bench according to claim 6, characterized in that, The operation panel (7) includes: The start button, stop button and emergency stop button are all self-resetting buttons with LED indicator lights, located on the left side of the operation panel (7) and electrically connected to the PLC controller of the control unit (2); The adjustment knobs, including the speed adjustment knob and the load adjustment knob, are located in the middle area of ​​the operation panel (7) and are electrically connected to the frequency conversion drive module and the load body of the control unit (2), respectively.

9. A gearbox test bench according to claim 8, characterized in that: The operation panel (7) also includes a status indicator group, which includes a power indicator, a running indicator and a fault indicator. It is located on the right side of the operation panel (7) and is electrically connected to the PLC controller of the control unit (2).

10. A gearbox test bench according to claim 1, characterized in that, The cabinet door (8) includes: The first cabinet door (13) is provided in the cooling medium storage chamber of the movable platform (1), and a liquid level observation window is provided on its inner side for observing the remaining amount of cooling medium. The second cabinet door (14) is located adjacent to the first cabinet door (13). The second cabinet door (14) is equipped with a spare parts storage cavity and a cable storage cavity for storing test fixtures, sensor spare parts and cables.

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