Hybrid test method, in particular for a wind turbine drive train

EP4612472A1Pending Publication Date: 2025-09-10FRAUNHOFER GESELLSCHAFT ZUR FORDERUNG DER ANGEWANDTEN FORSCHUNG EV
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Patent Information

Application Number
EP2023798793
Authority / Receiving Office
EP · EP
Patent Type
Applications
Current Assignee / Owner
Priority Date
2022-11-01
Filing Date
2023-11-01
Publication Date
2025-09-10

AI Technical Summary

Technical Problem

Existing powertrain test benches for wind turbines are often too small or weak to meet the increasing performance and load testing requirements, leading to high costs and difficulties in implementing comprehensive validation across development stages due to limited testing capacity.

Method used

A hybrid test method that involves conducting partial load tests on a test stand with a simulation model validation, allowing for the simulation of full load and overload conditions without the need for a test stand capable of applying the full load, thereby reducing infrastructure costs and energy requirements.

Benefits of technology

This method enables accurate simulation of full load and overload conditions using smaller, less expensive test stands, reducing testing costs and extending the life of existing infrastructure while providing validated simulation models for multiple scenarios, thus achieving equivalent results to full load tests without the need for high-capacity test benches.

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Abstract

The invention relates to a hybrid test method for determining a behaviour of a test specimen, in particular a wind turbine drive train, under predefined loads. A test stand with a test specimen to be tested is provided, wherein the test stand has a maximum applicable load that can be applied to the test specimen by the test stand, wherein a full load is predefined for the test specimen, wherein the full load of the test specimen is greater than the maximum applicable load of the test stand. The test stand is operated to perform a mechanical partial load test on the test specimen, wherein the test specimen is subjected to a partial load that is less than the full load of the test specimen and less than or equal to the maximum load that can be applied to the test stand. A simulation model for testing the test specimen is validated using the results of the partial load test. The validated simulation model is used to simulate load tests of the test specimen under full load and / or overload.
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Description

[0001] Hybrid test procedure, especially for a drive train of wind turbines

[0002] The present disclosure relates to a test method for determining a behavior of a test object, in particular a drive train of wind turbines.

[0003] The demands on test benches for mechanical drive systems, especially for wind turbines (WTs), are increasing with the increasing size of the test specimens. Many existing test benches for drive trains are already too small and / or too low-performance for the testing requirements of modern wind turbines.

[0004] In the current state of the art, growing test requirements regarding performance and / or the loads to be introduced are met by building larger test benches, for example, for testing a wind turbine nacelle or a wind turbine drive train. However, the implementation of ever larger test benches is associated with disproportionately increasing costs and effort. As a result, the widely used validation approach within the framework of product development according to the V-model, i.e., validation at various development stages during product development, is difficult to implement at the "drive train" system level, since many existing test facilities already do not offer the required test capacity for the entire, specified operating range (idle, partial load, full load, overload) for current and future drive train prototypes.

[0005] The present invention is therefore based on the object of proposing an alternative testing method. This object is achieved by a testing method according to claim 1. Advantageous developments of the method are set forth in the dependent claims and the following description. Exemplary embodiments of the method according to the invention are explained in more detail in the description of the figures.

[0006] The proposed hybrid test procedure is used to determine the behavior of a test object, in particular a drive train of wind turbines, under predefined loads. The test procedure comprises the following steps:

[0007] I. Providing a test bench with a test specimen to be tested, wherein the test bench has a maximum load that can be applied to the test specimen by the test bench, wherein a full load is predefined for the test specimen, wherein the full load of the test specimen is greater than the maximum load that can be applied to the test bench, II. Operating the test bench to carry out a mechanical partial load test on the test specimen, wherein the test specimen is subjected to a partial load that is smaller than the full load of the test specimen and less than or equal to the maximum load that can be applied to the test bench,

[0008] III. Providing a simulation model for testing the test object,

[0009] IV. Validate the simulation model using the results of the partial load test in step II,

[0010] V. Simulate a load test of the test object under full load and / or overload in the validated simulation model.

[0011] The maximum load that can be applied to the test specimen by the test bench can therefore be lower than the full load of the test specimen. For example, a test bench that is significantly smaller than one that could apply the full load of the test specimen can be used to test the test specimen. The investment costs for such a test bench can be significantly lower than for a test bench that could simulate the full load of the test specimen.

[0012] In this case, full load can be understood as a maximum load specified by the manufacturer. Full load can therefore be, in particular, the maximum load for which the test specimen was designed. For a machine, full load can correspond to the state of maximum power. Overload can be understood as a load above full load.

[0013] In step V, in particular, a load range can be simulated. A lower limit of the load range can, in particular, be greater than or equal to the maximum load that can be applied to the test object by the test bench. An upper limit of the load range can be less than or equal to the full load of the test object and / or less than or equal to a defined overload of the test object. A simulation of the load range can consist of repetitions of sequential and / or simultaneous simulations of individual load cases in the corresponding load range. Carrying out the mechanical tests at partial loads can result in lower energy consumption and / or a smaller number of tests having to be carried out in reality compared to testing on a test bench with higher performance. Both of these can lead to lower testing costs. In addition, there can be no need to invest in larger orto invest in more powerful test bench infrastructure as soon as initial test requirements exceed existing test bench capacities. Existing smaller test benches can continue to be used to test a test object with higher operating power or load requirements. The operators of existing test benches usually have validated simulation models of the test benches based on data from multiple test campaigns. Furthermore, existing test benches can generally be expected to be more reliable (numerous errors have already been corrected) and operate more efficiently than newly commissioned test benches. Furthermore, the proposed method can be used to generate a validated simulation model that can also be used for other applications.A further advantage of the method can be that validated virtual models (in any number) can be used to test multiple test scenarios through parallelization. This can lead to time and cost savings, whereas in a physical test bench, typically only one test can be performed at a time.

[0014] The numbering of the steps can specify a sequence of execution, for example in ascending order. However, execution can also deviate from the ascending order. The steps can, for example, be carried out in the order I, II, III, IV, V. Alternatively, the steps can be carried out in the order I, III, II, IV, V or in the order III, I, II, IV, V. Steps I and III can be carried out simultaneously. Step I can be carried out before step II is carried out. Step V can, in particular, be carried out after step IV. Step IV can, in particular, be carried out after step II.

[0015] In one embodiment, the test bench applies the maximum load that can be applied to the test specimen in step II. This can be advantageous, for example, because it allows a load case to be mechanically tested that is comparatively close to the simulated load test in step V. Particularly in the case of non-linear behavior of the test specimen with increasing load, the quality of the simulation model can be improved if the simulation model can be validated in step IV with load cases that are comparatively close to the simulated load case.

[0016] In one embodiment, step IV may include simulating a load on the test specimen under the same partial load as in the partial load stress test of step II in the simulation model. The results of the partial load stress test of step II and the results of the partial load simulation may be compared.

[0017] In one embodiment, the simulation model can be adapted in step IV. In particular, an adaptation can take place if the results of the partial load stress test on the test bench and the partial load simulation are different and / or do not lie within a predefined tolerance range. In this way, the quality of the simulation model and / or the simulated results can be improved. The quality of the simulation model can, in particular, represent how similar a test simulated with the simulation model is to a test on a test bench under the same boundary conditions. The quality can be defined, for example, by a representation quality of the test in the simulation process. The more similar the results of a simulated test are to the results of the same test on the test bench, the better the quality can be.

[0018] In one embodiment, the simulation model can be adapted in step IV by adjusting the simulation model's parameters, particularly while the physical-mathematical model remains unchanged. Additionally or alternatively, the simulation model can be adapted in step IV by adapting the physical-mathematical model to the system description. New and / or modified parameters can be used in this process.

[0019] In one embodiment, step II can be repeated for at least one further partial load and / or at least two further partial loads and / or at least three further partial loads. Step II can be repeated for a plurality of partial loads. The one partial load or the plurality of partial loads can in particular be smaller than the maximum load that can be applied by the test bench. The results of the repeated test(s) can each be used to validate the simulation model in step IV. In this way, the accuracy of the simulation model can be improved. By conducting a plurality of tests, in particular, non-linear behavior of a test object can be detected. The quality of the simulation results in step V can be improved.

[0020] In one embodiment, to determine parameters for the simulation model in step IV, the results of the partial load stress test in step II can be used as a reference to adjust the simulation model so that the measurements from the partial load stress tests substantially correspond to the simulation results of the partial load stress test(s) in the simulation. This can increase the accuracy of the simulation model.

[0021] In one embodiment, the maximum load that can be applied by the test bench can be at least 40% and / or at least 50% and / or at least 60% and / or at least 70% and / or at least 90% of the full load of the test object.

[0022] The maximum load that can be applied to the test bench of at least 40% and / or at least 50% can have the advantage of allowing sufficient data to be collected on the test bench to validate the simulation model with comparative accuracy. Furthermore, test bench costs and / or dimensions can be kept comparatively low.

[0023] Ranges of at least 60% and / or at least 70% of the test object's full load can result in improved simulation model quality compared to methods with lower maximum test bench loads. Furthermore, test bench costs and / or dimensions can be kept comparatively low.

[0024] Ranges of at least 80% and / or at least 90% of the test specimen's full load can yield even better simulation results than methods with lower maximum loads. However, this increases test bench costs and / or dimensions compared to methods with test benches with lower maximum loads.

[0025] The maximum load that can be applied by the test bench can, for example, be a maximum of 99% and / or a maximum of 90% and / or a maximum of 80% and / or a maximum of 70% and / or a maximum of 65% and / or a maximum of 60% of the test specimen's full load. Test benches with very high maximum loads, for example, up to 99% and / or up to 90% of the test specimen's full load, can deliver very accurate results in the simulation process. Furthermore, a smaller and / or more cost-effective test bench can be used compared to a process that also includes full-load testing on the test bench. "Smaller" can be understood here as essentially "less powerful." Less powerful test benches can generally also be built with a smaller footprint. With a lower maximum load, the test specimen to be tested at partial load can still be integrated with the test bench, particularly geometrically / physically.

[0026] Methods using test benches that have high maximum loads that can be applied, for example, up to 80% and / or up to 70% of the test specimen's full load, can deliver accurate results in the simulation process. The cost savings compared to a test bench that can test the test bench's full load are significant. Additionally or alternatively, a comparatively smaller test bench can be used, which requires correspondingly less storage space. Particularly for applications where accuracy is not particularly demanding, it can be advantageous to use a test bench with a maximum load that can be applied of no more than 65% and / or no more than 60% of the test specimen's full load. Such a test bench is typically significantly smaller and less expensive than a test bench capable of applying higher loads.

[0027] It may be provided that the test specimen is subjected to various load tests. Steps I and / or II and / or III and / or IV and / or V can be performed repeatedly, for example, for different types of loads. In particular, steps II and IV and V can be performed repeatedly, for example, for different types of loads, for example, for a torsional moment and / or a bending moment and / or a tensile force and / or a compressive force. For each type of load, steps II and IV can be performed for one or more different partial loads.

[0028] In one embodiment, step V may include simulating a load test of the test object under overload in the validated simulation model. Overload may be defined, for example, as a load in a range of 120% to 200% of full load.

[0029] The proposed hybrid test method can be particularly suitable for testing a technical system subjected to loads on a test bench and / or a shaft-bearing unit of a drive train of a technical machine and / or a drive train of a wind turbine or a gear stage of a drive train or a motor vehicle cardan shaft or a planetary gear for wind turbines or a rolling bearing. Accordingly, the test object can be a technical system subjected to loads on a test bench and / or a shaft-bearing unit of a drive train of a technical machine and / or a drive train of a wind turbine and / or a gear stage of a drive train and / or a motor vehicle cardan shaft and / or a planetary gear for wind turbines or a rolling bearing.

[0030] The following description of the figures provides a more detailed explanation of exemplary embodiments of the method according to the invention. The features and combinations mentioned are not to be understood as limiting and serve merely as illustrations.

[0031] It shows

[0032] Fig. 1 is a schematic flow diagram illustrating a hybrid test procedure for determining the behavior of a test specimen under predefined loads,

[0033] Fig. 2 is a diagram showing proportions of measurement results from physical tests and simulation results as a function of load,

[0034] Fig. 3 shows an exemplary process diagram illustrating a hybrid test procedure for determining the behavior of a test object under predefined loads,

[0035] Fig. 4 shows an exemplary process diagram illustrating a hybrid test method for measuring the deformation of a machine support of a drive train of wind turbines (WT) under various combined loads,

[0036] Fig. 5 shows an exemplary process diagram illustrating a hybrid test procedure for testing a motor vehicle cardan shaft and

[0037] Fig. 6 shows an exemplary process diagram illustrating a hybrid testing method for testing gear deformation and planet carrier displacement of a gearbox for wind turbines.

[0038] Figure 1 shows a flowchart 100 illustrating a hybrid test method for determining the behavior of a test object under predefined loads. In a step 101, a test bench with a test object to be tested is provided. The test bench has a maximum load that can be applied to the test object by the test bench. A full load is defined for the test object. The full load of the test object is greater than the maximum load that can be applied to the test bench. In this case, the maximum load that can be applied to the test object is, for example, 80% of the full load of the test object. Furthermore, in a step 102, at least one simulation model 105 is provided that is designed to test the test object.

[0039] First, the test specimen is subjected to a mechanical load test on the test bench in step 103. The test conditions are predefined, and the test bench is set up accordingly. During the mechanical load test, the test specimen is subjected to a partial load. The partial load is less than the full load of the test specimen. The partial load is either less than or equal to the maximum load that can be applied by the test bench. In this case, the partial load applied to the test specimen during the test is, for example, 80% of the full load of the test specimen and thus corresponds to the maximum load that can be applied by the test bench. The mechanical load test has results 104. The results 104 are used to validate the simulation model 105, so that a validated simulation model 106 is generated. Using the validated simulation model 106, a load on the test specimen under full load is simulated, resulting in simulation results 107 of a full load loading of the test specimen.The mechanical load test according to step 103 can optionally be repeated for further partial loads of the test object, so that results 104 are also generated for these partial loads. The simulation model 105 can be validated with the results of these further tests, which increases the accuracy of the validated simulation model 106. This leads to optimized full-load simulation results 107. With the validated simulation model, simulations can be carried out over the entire specified load or operating range. In this way, the real measurement results of the test campaign in the load range below the nominal loads can be used in two ways: firstly, to validate one or more realistic simulation models and secondly, as measurement results for all (relevant) tests below the nominal loads. All further test results (full-load behavior and cross-range, so-calledThe large-signal response above the loads that can be introduced by the test equipment can be determined using the validated simulation models. The results of the mechanical load test(s) 104 and the results of the full-load simulation 107 can thus be combined to form results 108 across the entire load range.

[0040] Figure 2 shows a diagram 200 illustrating the respective proportions of measurement results from physical tests 201 and simulation results 202 for the test procedure according to Figure 1 over the load. Range 203 represents the load range that can be applied to the test specimen by the test bench. Load 204 is therefore the maximum load that can be applied by the test bench. Load 205 corresponds to the full load of the test specimen. By combining the results of the physical tests 201 and simulations 202, the entire load range 206 can be tested. In addition, the simulations can be extended back to the partial load range in order to investigate cross-range dynamic test scenarios, e.g., from idle to the full or overload range.While in conventional full-load tests, a test bench must have a capacity up to full load 205, in the method shown, the required test bench capacity 203 can be significantly reduced compared to the conventional full-load test. Tests can therefore be shifted to smaller, more cost-effective test benches (which, by their very nature, can also operate with higher accuracy); or systems that cannot currently be tested at full load can be tested on existing test benches, even though their load requirements may exceed the test bench capacity. Using the method shown in Figure 1, it is therefore possible to achieve equivalent results to the full-load test without having to rely on a test bench with maximum load introduction capacity.

[0041] Figure 3 shows a process diagram 300 illustrating an example of a hybrid test procedure for determining the behavior of a test object under predefined loads. The process diagram 300 shows a test procedure for a drive train of a wind turbine. In particular, loads, deformations, and oscillations or vibrations of the system are examined.

[0042] A simulation model 302 of a test bench with a virtual test object, in this case with a simulation model of a drive train of a wind turbine, is provided. Information 301 is fed into the simulation model 302. The information can, for example, include specified loads, for example static loads and / or torques. The loads can, for example, be partial loads in the range of 50 - 60% of the full load 308. In the simulation model, the behavior of the drive train under the specified loads can be investigated by simulation. The simulation provides results 303 as output. The results 303 of the simulation can, for example, be or include information on loads and / or deflection and / or deformations and / or stresses and / or vibrations of the test object. In particular, the behavior of the test object, here the drive train, under partial load can be simulated.The results concerning the virtual test specimen can be applied to the real test specimen.

[0043] Furthermore, a test bench 304 is provided, into which a real test object, in this case the drive train of the wind turbine, is integrated for testing. The test object is tested on the test bench, whereby the test object is subjected to the same loads as the virtual test object in the simulation. The test provides results 310 as output. The results 310 of the test can, for example, be or include information on loads and / or deflection and / or deformations and / or stresses and / or vibrations of the test object. In a step 305, the results 310 of the test are compared with the results 303 of the simulation. If the results 310 of the test correspond to the results 303 of the simulation or if the deviation is less than or equal to 5%, a further simulation 306 is carried out.If the test results 310 deviate from the simulation results 303 by more than 5%, the simulation model is adjusted, in particular based on information from the test, as symbolized by arrow 307. The possibly adjusted simulation model 302 is used for the simulation 306. The simulation is carried out under full load conditions 308 and, as result 309, provides information on the behavior of the test object, here the drive train of the wind turbine, under full load conditions. Using the method according to Figure 3, it is therefore possible to achieve equivalent results to the full load test without having to rely on a test bench with maximum load introduction capacity. Of course, other tolerances for deviations can also be provided, for example 0.1% or 1% or 2% or 10% or 15% or 20%.

[0044] The quality of the results from the simulated tests can essentially be determined by the quality (accuracy) of the previously validated test specimen models. In the simplest case, the test specimen can exhibit consistently linear operating and system behavior. In this quasi-trivial case, the test specimen's behavior in the full-load range can be simulated without any further steps using the test specimen models identified and validated through partial load testing. However, the systems under test may exhibit nonlinearities. For the above procedure, a ratio between the test specimen load and the test bench load capacity can be assumed, in particular between 1.001 and 100, in particular 1.3 and 3, and in particular 1.5 and 3. This can have the advantage that nonlinearities of the test specimen can be measured comparatively well even in the partial load range during the physical test bench tests.The quality of the nonlinear test specimen models derived from bench tests can be determined essentially by the type of model, the identification of nonlinearities, and their parameter-dependent (operating state- and load-dependent) extrapolation into the full-load range. Proven methods for the parametric and non-parametric identification of system behavior can be used to identify nonlinear system behavior. For example, neural networks, general machine learning methods, or regression and optimization methods can be used. If the nonlinearities can be described using multilinear polynomials, optimization techniques in conjunction with tensor calculations can be advantageously used.

[0045] Figure 4 illustrates in a process diagram 400 a hybrid test method for measuring a deformation of a test specimen, in this case a machine carrier of a drive train of wind turbines (WT) under various combined loads.

[0046] The method is intended to investigate the deformation of the machine frame at the gearbox support, for example, to ensure that the yaw bearing and drive are not subjected to excessive loads due to a deformed machine frame. Combined loads from rotor torques, bending forces, and transverse forces were previously determined as the load cases to be investigated.

[0047] A simulation model 402 of the test bench with the test specimen is provided. The simulation model may, for example, already exist and have been created as part of the design / development of the drive train. In particular, the simulation model may be an FE simulation model. In this simulation model 402, FE simulations of the deformation of the machine support may already have been performed. The simulations may, for example, not be validated. Due to numerous assumed model and material parameters, the results may therefore be subject to a certain degree of uncertainty. Therefore, a test under full load should confirm / validate the design assumptions.

[0048] For this purpose, a full-size test could be conducted on a test bench for wind turbine drive trains, in which the loads considered critical are introduced at the intended magnitude. However, test benches with the required load introduction capacity are rare and expensive. Using the method in Figure 4, the test can also be conducted on a test bench 404 that cannot fully achieve the intended loads—in this case, for example, only approximately 50-70% of the target load.

[0049] The test specimen is tested in its actual size on the "undersized" test bench 404, whereby the loads 401 do not fully correspond to the target loads due to the test bench limitations, but are scaled down according to the test bench capacity. For example, the test specimen has a full-load torque of 12 MNm. However, the test on test bench 404 is carried out at a partial load, namely a torque of 8 MNm. For example, the test specimen has a full-load bending moment of 24 MNm. However, the test on test bench 404 is carried out at a partial load, namely a bending moment of 16 MNm. In other examples, the actual applied loads can be the maximum loads of the test bench; a proportional scaling of the target loads is not necessarily required.

[0050] The physical tests conducted yield initial measurement results 410 for the desired target variable "deformation of the machine support (e.g., in the x- and y-direction)", which in the example can be presented as time series from a distance sensor (e.g., laser distance measurement). Individual target loads below the test bench capacity may have already been reached, but overall, the desired results under the target load cannot be determined from the physical tests.

[0051] Based on these measurement results 410 of the physical tests at partial load, a new simulation model 406 is now created and parameterized, which can precisely reproduce the physical test results of the relevant sensors. The model 402 already developed for the design can also be used for this purpose and fitted / adjusted with appropriate parameter corrections. In the known simulation model 402, the same partial loads 401 are set that were tested in the test on the test bench 404 (in this case, a bending moment of 16 MNm and a torque of 8 MNm). The results 403 of the simulation with the simulation model 402 are validated with the results from the test on the test bench 404 in step 405. The simulation model is adjusted (symbolized by the arrow 407) until the results of the adjusted simulation model 402 essentially agree with the test results.The final, adjusted simulation model then corresponds to the validated simulation model 406. Where necessary, e.g., due to coupling effects, the test bench can also be represented in the simulation model. The validated simulation model 406 is capable of outputting the measured variable of interest (deformation of the machine support) with significantly greater accuracy than a non-validated simulation model or a simulation model that is not adjusted to the test results. The simulation model therefore delivers accurate results up to the level of the loads introduced in the physical test, as it has been optimized for these measurement results. With this partial-load validated simulation model, simulations are now performed under the desired target loads 408, which could not be reached in the physical test. Virtual tests are therefore performed at full load.From these simulations, the expected deformations 409 of the machine frame at full load and / or overload can be determined with high accuracy. This eliminates the need for additional physical tests at the actual target loads. In combination, the measurement results from the physical tests at partial load and the virtual test results from the simulations with the partial load-validated simulation model provide comparable information to a physical test conducted at the target loads.

[0052] Figure 5 illustrates, in a process diagram 500, a hybrid test method for testing a motor vehicle propeller shaft. The method essentially corresponds to the methods described in Figures 1 to 4. 504 is a test bench for examining motor vehicle propeller shafts. The test bench can apply speed, torque, spring travel, and steering movement to the test specimen according to the load profiles. Parameters such as speed, torque, spring travel, deflection angle, or joint temperature are measured or controlled. The test capacity is limited by the maximum torque and the range of spring movement (spring travel, speed, acceleration) that the test bench can apply. The test specimen, i.e., the motor vehicle propeller shaft, is tested within the capacity of the test bench 504 at partial load 501. The partial load 501 lies, in particular, in a range of 50-60% of the full load 508.This is generally only part of the test range in relation to the desired test requirements. A virtual model 502 of the test bench with the test specimen is available. Using the virtual model 502, the test is carried out virtually under partial load conditions 501. Results 503 are generated in the process. The test results 510 of the test on the test bench 504 (e.g., the measured axial force and torsional play) are used to validate (symbolized by the arrow 507) the virtual model 502 of the test specimen (and, if applicable, the test bench) under the same partial loads in step 505, so that a validated virtual model 506 is generated. Using the validated virtual model 506, the remaining full loads 508 can be simulated and results 509 at full load can be determined. In this case, the results 509 can be present, for example, as an axial force corresponding to the full loads and as a torsional play reaction.

[0053] Figure 6 illustrates, in a process diagram 600, a hybrid test method for testing gear deformation and planet carrier displacement of a gearbox for wind turbines. The method essentially corresponds to the methods described in Figures 1 to 5. 604 is a gearbox test bench. Gearbox test benches are an important and certification-relevant component of the development process for wind turbines that have a gearbox. The gearbox test bench 604 can, for example, apply torque and / or bending and / or thrust and / or shear loads. In this case, for example, the deformation of the gearing and the displacement of the so-called planet carrier can be examined. The test bench 604 has specific limits for the level of the maximum loads that can be applied.With the hybrid test method presented here, the transmission's response to loads that exceed the test bench's load capacity can be determined based on the partial load-validated virtual model 606 with significantly improved quality compared to a non-validated model 602. First, the transmission is tested with partial loads 601, for example, with torque and / or bending loads within the capacity of the test bench 604. Test results 610 are generated. These loads 601 may only lie within a partial test range that meets the desired test requirements. During these partial load tests, the deformation of the gearing and the resulting displacement of the planet carriers are measured. Results 603 are determined for the same partial loads using a virtual model 602.The measured test results 610 are used to validate 607 the virtual model 602 of the transmission to be tested (and the test bench, if necessary) for the same partial loads, generating a validated model 606. Using the validated virtual model 606, the remaining full loads 608 can be simulated, and results 609 in the form of tooth deformation and planet carrier displacement corresponding to the full loads can be determined.

[0054] The partial load 601 can, for example, be 50-60% of the full load 608.

Claims

Patent claims Hybrid test method for determining the behavior of a test object, in particular a drive train of wind turbines, under predefined loads, the test method comprising the following steps I. Providing a test bench with a test specimen to be tested, wherein the test bench has a maximum load that can be applied to the test specimen by the test bench, wherein a full load is predefined for the test specimen, wherein the full load of the test specimen is greater than the maximum load that can be applied to the test bench, II. Operating the test bench to perform a mechanical partial load test on the test specimen, whereby the test specimen is subjected to a partial load that is less than the full load of the test specimen and less than or equal to the maximum load that can be applied by the test bench, III. Providing a simulation model for testing the test object, IV. Validate the simulation model using the results of the partial load test in step II, V. Simulating a load test of the test object under full load and / or overload in the validated simulation model. The hybrid test method according to claim 1, wherein the steps are performed in the order I, II, III, IV, V, or in the order I, III, II, IV, V, or in the order III, I, II, IV, V. The hybrid test method according to claim 1 or 2, wherein in step II, the test bench applies the maximum load that can be applied to the test object.

4. Hybrid testing method according to claim 1, 2 or 3, wherein step IV comprises simulating a load of the test specimen under the same partial load as in the partial load load test of step II in the simulation model, and comparing the results of the partial load load test of step II and the partial load simulation.

5. Hybrid test method according to claim 2 or 3, wherein in step IV the simulation model is adapted if the results of the partial load test in the test bench and the partial load simulation are unequal and / or do not lie within a predefined tolerance range.

6. Hybrid test method according to one of the preceding claims, wherein step II is repeated for at least one further partial load, wherein the partial load is smaller than the maximum load that can be applied by the test bench, and the results of the repeated test are used to validate the simulation model in step IV.

7. Hybrid test method according to one of the preceding claims, wherein in step IV, to determine parameters for the simulation model, the results of the partial load stress test in step II are used as a reference in order to adapt the simulation model such that the measurements from the partial load stress tests substantially correspond to the simulation results of the partial load stress test(s) in the simulation.

8. Hybrid test method according to one of the preceding claims, wherein the maximum load that can be applied by the test bench is at least 40% and / or at least 50% and / or at least 60% and / or at least 70% and / or at least 90% of the full load of the test object and / or wherein the maximum load that can be applied by the test bench is at most 99% and / or at most 90% and / or at most 80% and / or at most 70% and / or at most 65% and / or at most 60% of the full load of the test object. Hybrid test method according to one of the preceding claims, wherein steps II to V are repeatedly performed for different types of loads. Hybrid test method according to one of the preceding claims, wherein the test object is a technical system that is subjected to loads on a test bench and / or the test object is a shaft-bearing unit of a drive train of a technical machine and / or the test object is a drive train of a wind turbine or a gear stage of a drive train or a motor vehicle cardan shaft or a planetary gear for wind turbines or a rolling bearing.