Gearbox Drive Test Bench with Simulated Axial and Radial Loads
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing test methods for gearboxes do not adequately simulate real-world loads and conditions, particularly in applications where the gearbox output shaft is vertically oriented, leading to potential safety issues due to improper lubrication and structural integrity testing.
Innovation Solution
A test bench system utilizing an electric motor-driven gearbox with a rotationally fixed output shaft connected to a first shaft via a coupling, incorporating controllable linear actuators to apply time-dependent forces, allowing simulation of axial and radial loads, and a compensating tank to manage thermal expansion, ensuring reliable and efficient testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gearbox is tested with vertically oriented output shaft as in real applications, then the lubrication conditions and structural integrity are properly simulated, but the testing complexity and setup requirements increase significantly
Solution Approach 1:
The patent inverts the testing approach by testing the gearbox with a horizontally oriented output shaft instead of the vertically oriented configuration used in actual applications (mixers, agitators). This inversion simplifies the test bench setup while maintaining testing validity through compensatory measures.
Solution Approach 2:
The patent changes the orientation parameter of the output shaft from vertical to horizontal during testing. Additionally, it uses controllable linear actuators to dynamically adjust and apply forces that simulate the equivalent load conditions of vertical operation, thereby maintaining testing accuracy despite the orientation change.
2Reliability
If controllable linear actuators are used to apply time-dependent periodic forces to simulate real loads, then the simulation accuracy of operational conditions is improved, but the device complexity and control requirements increase
Solution Approach 1:
The patent employs controllable linear actuators to apply time-dependent periodic forces to the gearbox, simulating the cyclic load patterns encountered during actual operation. This periodic action accurately reproduces real-world operational conditions while using standardized actuator control mechanisms.
Solution Approach 2:
The linear actuators serve multiple functions: they apply radial forces, simulate dynamic load variations, and can be controlled through a unified control system. This multi-functionality reduces the need for separate testing devices while maintaining comprehensive load simulation capabilities.
3Reliability
If the output shaft is connected to a shaft outside the gear unit, then forces can be applied to the bearing to simulate real application loads, but the structural complexity of the test setup increases
Solution Approach 1:
The patent introduces a first shaft as an intermediary element between the gearbox output shaft and the linear actuators. This intermediate shaft enables force application to the bearing while maintaining a modular and manageable structural configuration, avoiding direct complex coupling between actuators and the gearbox.
4Weight of moving object
If the gearbox is partially filled with oil to reduce mass, then the gear unit mass is reduced and expansion tank is eliminated, but the lubrication coverage may be insufficient under all operating conditions
Solution Approach 1:
The patent applies partial filling of the gearbox with oil, using only the minimum necessary amount to ensure adequate lubrication of critical components during testing. This partial action reduces the gearbox mass and eliminates the need for an expansion tank while maintaining sufficient lubrication coverage for reliable operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively simulates operational loads on gearboxes, ensuring proper lubrication and structural integrity, reducing the risk of leaks and enhancing safety by accurately replicating conditions in applications like mixers and agitators.
Implementation Method 1
an axial bearing which can be acted upon by at least one controllable first linear actuator with a time-dependent periodic force
Implementation Method 2
the first shaft is connected to a generator unit via a cardan shaft, in particular by means of cardan joints, in particular in a rotationally fixed manner
Implementation Method 3
the drive is connected to a compensating tank such that the interior of the first transmission is completely filled with oil, and thermally induced expansion of the oil is absorbed in the interior of the compensating tank
Implementation Method 4
an axial bearing which can be acted upon by at least one controllable first linear actuator with a time-dependent periodic force
Data Source
Figure 1
AI summary
The invention relates to a drive and a method for operating a drive, comprising an electric motor and a first gearbox that can be driven by the electric motor, wherein an output shaft of the first gearbox is connected to a first shaft in a rotationally fixed manner by means of a coupling, in particular a rigid shaft coupling, wherein the first shaft is supported by an, in particular single axial bearing that can be loaded with a force by at least one controllable first linear actuator.