Gearbox Proof Testing

Gearbox Manufacturing, Repairing, Prototyping:

It is summarized below the type of testing that we usually perform for gearbox qualification and proof testing. The gearbox optimization and productivity require application load case or load spectra measurement. The structural analysis includes gear meshes, shafts, and bearings, housing and lubrication optimization. After prototyping the gearbox testing should be performed on automated gear tester rig. Several important tests are required in our lab in order to validate the product.

• Assembly phase verification
• Shimming axial play verification
• QC measurement of all components and functional fit
• Assembly gearbox check
• Structural testing
• Endurance testing
• Thermal analysis
• Noise certification
• Vibration testing

Temperature testing:

• Gearbox inside components testing with thermocouples
• Gearbox rotating parts & outside wall testing with infra camera
• Temperature rise of HALT & endurance testing may require forced lubrication or air cooling
• Endurance testing (automated load case spectrum programmed on brake)
• Experiment to validate functionality
• Anti-back drive testing

Additional testing:

• Noise certification (dB)
• Vibration test on bearings and housing
• No load testing, load testing power loss measurement
• Gearbox efficiency testing (on different RPM, and load)
• Backlash testing (On output shaft)
• Tooth wear or continuous backlash testing with gear flank wears measurement
• Lubrication churning test, oil splash and power loss testing
• Gearbox impact test with weight