This rig is ideal for organisations that can’t afford guesswork on gearbox reliability: • Armoured vehicle and tracked platform manufacturers ▹Routine testing and final acceptance of side gear boxes. • Ordnance factories and heavy vehicle overhaul depots ▹Post-repair and post-overhaul performance verification before re-induction. • Defence R&D and engineering labs ▹Design validation, benchmarking, oil and configuration comparison testing. • Independent test houses and private heavy-equipment facilities ▹Contract testing for OEMs and maintenance organisations.
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In tracked combat vehicles and heavy armoured platforms, the side gear box sits right where everything hurts the most: high torque from the engine, sudden shock loads from rough terrain, heat soak from long missions, and constant directional changes. It doesn’t get any glory, but if it fails, the vehicle stops moving. No steering, no manoeuvre, no mission. This rig exists to make the side gear box prove itself under controlled, instrumented abuse before it ever touches a vehicle. The Electrical & Hydraulic System for the Side Gear Box (LH & RH) Test Rig is built as a production-grade test facility, not a token test stand. Instead of just spinning the input shaft for a few minutes and ticking a checklist, it recreates the real operating envelope: • The lubricant is heated to high, realistic temperatures, not just lukewarm shop conditions. • Oil is pumped through the gearbox under pressure, so lubrication paths and clearances are properly challenged. • A controlled brake load is applied to make the gear train work, not freewheel. • Clutch and gear shift cylinders are actuated hydraulically, mimicking actual vehicle actuation forces and sequences. • Torque, RPM, temperature, pressure, noise and vibration are monitored in real time, so you see exactly how the gearbox behaves, not just whether it survived. Under the hood, the rig combines: • High-capacity lubrication and actuation hydraulic power packs • A high-power asynchronous servo drive to apply controlled mechanical energy • Dedicated hydraulic circuits for oil circulation and actuation functions • A PLC–HMI based automation and data acquisition platform • A tightly integrated sensor suite designed for serious diagnostic, QA and development work Put simply, this machine turns side gear box testing from a subjective “sounds okay” judgement into a repeatable, data-driven validation process – effectively a side gear box test laboratory in one integrated system. 1. Purpose & Functional Scope The rig is designed for comprehensive, repeatable testing of both Left-Hand (LH) and Right-Hand (RH) side gear boxes, including multiple variants of the same family. It is suitable for both production QA and R&D. It allows you to: • Validate mechanical performance ▹Check whether the gearbox can transmit the required torque without abnormal noise, vibration or overheating. ▹Confirm correct functioning in all gears under both light and heavy load. • Verify shift and actuation behaviour ▹Evaluate smoothness and repeatability of clutch engagement/disengagement. ▹Confirm that the gear shift mechanism reaches and positively holds each gear position. ▹Check brake actuation under controlled hydraulic load while the system is rotating. • Assess thermal and lubrication performance ▹Study oil temperature rise under sustained loading and endurance runs. ▹Examine how the gearbox behaves at elevated oil temperatures closer to real service conditions. • Analyse NVH and fatigue trends ▹Capture noise and vibration signatures across the full speed range. ▹Identify early signs of misalignment, bearing damage, gear tooth pitting or other internal issues. • Standardise acceptance criteria ▹Run standardised test cycles for every gearbox leaving the factory. ▹Log parameters for traceability and correlation with any field feedback. 2. Hydraulic Architecture The hydraulic system is split into two logical subsystems: 1. Lubrication / oil circulation & heating 2. Actuation (clutch, gear shift, brake) This separation improves reliability, control and ease of maintenance. 2.1 Lubrication & Oil Circulation System The lubrication system is responsible for circulating conditioned oil through the gearbox under realistic conditions. Key characteristics: • 400-litre insulated tank ▹Large volume to provide thermal stability and enough reserve for extended endurance tests. ▹Designed to minimise aeration and ensure reliable suction and return. • High-temperature oil capability ▹Uses high-grade gear oil compatible with heavy-duty side gear box applications. ▹Approx. 20 kW immersion heater for fast heat-up and stable high-temperature operation. ▹Oil temperature capability up to around 150°C for worst-case, severe-duty simulations. • Pressurised circulation ▹Delivery pressure around 18 kgf/cm2, ensuring oil reaches internal galleries and critical contact points. ▹Multi-stage filtration (coarse + fine) to maintain oil cleanliness and protect the gearbox and pumps. • Thermal performance window ▹Typical return oil temperature during testing targeted around 100 ± 10°C. ▹This window allows assessment of sealing, clearances, noise/vibration and efficiency in hot running conditions. Practically, you are testing the gearbox hot, loaded, and properly lubricated, exactly how it will run in service. 2.2 Actuation Power Pack (Clutch, Gear Shift & Brake) The actuation side is a separate hydraulic system that drives the clutch, gear-shift and brake mechanisms. This subsystem includes: • 40-litre hydraulic reservoir ▹Dedicated to actuation functions, separate from lubrication oil. ▹Reduces cross-contamination and simplifies control. • High-pressure actuation circuit ▹Working pressure up to roughly 40 kgf/cm2. ▹Provides sufficient force and speed for all actuation cylinders. • Dedicated cylinders for each function ▹Clutch actuation cylinder – for controlled clutch engagement/disengagement. ▹Gear shift cylinder – moves the selector to the required gear position. ▹Gear shift block/locking cylinder – ensures the gear is positively held in the commanded position. ▹Brake actuation cylinder – applies controlled braking torque to load the gearbox during testing. • Hydraulic distribution mechanism ▹Directs flow and pressure to each cylinder according t ▹the PLC-controlled test sequence. ▹Enables complex, repeatable cycles such as: ▪ Engage clutch → select gear → apply brake → run at load → release → shift to next gear. This gives you repeatable, programmable actuation that mimics real control inputs far more accurately than any manual lever operation. 3. Electric Drive System 3.1 High-Power Asynchronous Servo Motor Mechanical energy is supplied by a robust asynchronous servo motor designed for test bench duty. Key aspects: • Rated power: approx. 78–80 kW • Maximum speed: up to about 2500 RPM • Built for: ▹High starting torque demands. ▹Frequent speed changes and transients. ▹Continuous-duty endurance tests. Compared to a standard induction motor, the servo configuration allows tight control over speed and torque, which is critical when you want repeatable, measurable test conditions, not just “run and see”. 3.2 Servo Drive & Control The servo motor is commanded by a servo drive system integrated with the PLC: • Closed-loop control using encoder feedback on the motor. • Supports: ▹Constant-speed running for endurance and heat soak. ▹Controlled speed ramps for performance mapping. ▹Step changes and transient profiles for shock/load simulation. • Incorporates protective functions: ▹Over-current and overload protection. ▹Over-temperature protection for motor and drive. ▹Controlled stop and safe shutdown on faults or emergency stop. You get a programmable drive profile for the gearbox, rather than a simple ON/OFF motor. 4. Torque & Performance Measurement Torque is measured directly on the shaft with an inline torque sensor: • Measurement range: typically around 0–300 Nm • Mounted between the motor output shaft and the gearbox input shaft. • Captures: ▹Torque vs. speed characteristics in each gear. ▹Transient torque behaviour during clutch engagement and gear shifts. ▹Changes in torque requirements as the oil heats up and components expand. With this, you can build a clear “good gearbox” torque signature and detect any deviation in suspect units early. 5. Instrumentation & Sensors This rig is an instrumented test platform, not just a mechanical load machine. The sensor suite provides full visibility into how the gearbox behaves. 5.1 Process & Condition Sensors Core sensors include: • RPM Sensor ▹Measures rotational speed across the full operating range. ▹Used to synchronise torque, vibration and noise data against speed. • Temperature Sensors (PT100 RTDs) ▹Installed in the lubrication tank and key lines. ▹Range adequate for hot oil operation (0–150°C). ▹Used both for monitoring and for closed-loop temperature control and safety. • Pressure Transmitters ▹Installed in lubrication and actuation circuits. ▹Monitor: ▪ Lubrication pressure health. ▪ Cylinder pressures during clutch, gear shift, and brake actuation. • Noise Sensor ▹Measures overall gearbox noise level. ▹Useful for NVH comparison between units and over time. • Tri-axial Vibration Sensor (Accelerometer) ▹Captures vibration in three orthogonal axes. ▹Wide frequency range to pick up gear mesh frequencies, bearing issues and structural resonances. 5.2 Why This Matters With all these signals correlated (torque, RPM, pressure, temperature, noise, vibration), the rig becomes a diagnostic and development tool: • You can distinguish lubrication issues from design flaws. • You can detect early mechanical problems long before catastrophic failure. • You can generate reliable, data-backed acceptance criteria for every gearbox. 6. PLC–HMI Automation & Data Acquisition 6.1 PLC (Programmable Logic Controller) The PLC is the central control unit that coordinates all subsystems. Responsibilities include: • Sequencing of test routines ▹Oil heating and circulation start/stop. ▹Motor run-up, steady operation and run-down. ▹Clutch, gear-shift and brake actuation in a defined order. • Safety logic enforcement ▹Over-temperature shutdown. ▹Low lubrication pressure alarms. ▹Emergency stop processing. ▹Interlocks to prevent mechanically unsafe states. • Real-time control ▹Adjusts speeds or pressures based on feedback. ▹Ensures that each step of a test sequence completes before moving to the next. 6.2 HMI (Human–Machine Interface) The operator interacts with the rig via a graphical HMI panel: • Real-time visualisation of: ▹Gearbox speed and torque. ▹Oil temperatures and pressures. ▹Actuation system status. ▹Active alarms and warnings. • Operator functions: ▹Start/stop of complete test sequences. ▹Selection of test recipes for different gearbox variants. ▹Limited manual control modes for maintenance or investigation. ▹Viewing basic trends and key parameter histories (depending on configuration). Together, the PLC–HMI system ensures the rig can be used daily by operators while still providing enough depth and control for development engineers. 7. Mechanical Layout & Hydraulic Circuit Integration The mechanical and hydraulic layout is engineered for clarity, access and serviceability: • Modular physical layout ▹Main 400 L lubrication power pack as one module. ▹40 L high-pressure actuation power pack as another. ▹Electrical/servo drive panel in a dedicated cabinet. ▹Operator console / HMI placed ergonomically for visibility and control. • Logical hydraulic routing ▹Correctly sized suction and return lines to avoid cavitation. ▹filters positioned for easy access and regular maintenance. ▹Clearly marked manifolds, valves, gauges and test points. • Ease of maintenance ▹Structural arrangement allows pumps, motors, valves and sensors to be replaced with minimal disassembly. ▹Clear documentation and circuit representation support quick troubleshooting. This keeps downtime under control and ensures the rig remains practical to operate for many years. 8. Technical Specifications
