500kW One-to-One Forced Air Cooling Gearbox And Axle Performance Testing And Reliability Testing Bench

 500kW One-to-One Forced air cooling Gearbox and Axle Performance Testing and Reliability Testing Bench

The 500KW gearbox performance test bench is a device specially used to carry out performance and reliability evaluation on components such as transmissions and drive axles. It can realize multiple tests such as efficiency, power performance, comprehensive performance and long-term reliability of the tested parts.

The 500KW gearbox durability test bench mainly includes the following key parts: an input dynamometer system with both driving and loading functions; an output dynamometer system that can realize loading and reverse driving; a variable frequency inverter that can transmit electrical energy back to the power grid; a control system responsible for overall regulation; a data acquisition component for recording various parameters; a bench mechanical frame that supports the overall structure; oil station equipment that provides lubrication guarantee; and a video surveillance device that monitors the operating status in real time.

1. 500kW One-to-One Forced air cooling Gearbox and Axle Performance Testing and Reliability Testing Bench Components

• Input dynamometer system (drive and load): on the one hand, it provides power input to the gearbox to simulate the working state of the engine; on the other hand, it can apply load to simulate the resistance of the vehicle when driving, so as to test the performance and durability of the gearbox under different loads.
• Output dynamometer system (loading and driving): mainly used to absorb the power output of the gearbox, and can also reverse drive the gearbox to simulate vehicle braking, downhill and other working conditions, and further comprehensively test the performance of the gearbox.
• Variable frequency inverter system: It can recycle the electric energy generated during the test and feed it back to the power grid, realizing the recycling of energy, reducing the test cost, and reducing energy waste and environmental impact.
• Control system: It is the "brain" of the test bench and is responsible for setting test parameters (such as speed, torque, gear, etc.), controlling the coordinated work of various systems, and ensuring that the test is carried out accurately and stably according to the preset procedures.
• Data acquisition system: collects various data in the test process in real time, such as speed, torque, temperature, pressure, vibration, etc., and performs preliminary processing and storage on the data to provide a basis for subsequent analysis and evaluation.
• Test bench mechanical system: including base, bracket, connecting shaft and other structural components, used to fix gearbox, dynamometer and other equipment, ensure precise connection and stable operation between components, and reduce the impact of vibration and displacement on test results.
• Oil station system: provides lubricating oil to the gearbox, controls parameters such as oil temperature and oil pressure, ensures that the gearbox works under appropriate lubrication conditions, and can also evaluate the wear condition of the gearbox by monitoring indicators such as oil contamination.
• Video monitoring system: Real-time monitoring of the test bench's operating status and changes in the gearbox's appearance, allowing for timely detection of abnormal conditions (such as oil leakage, abnormal noise, component damage, etc.) to ensure the safety of the test process.

2. 500kW One-to-One Forced air cooling Gearbox and Axle Performance Testing and Reliability Testing Bench Working Principle

Before the test begins, the operator sets the test parameters through the human-machine interface, and the control system sends instructions to the drive system and the load system. The drive system drives the gearbox to operate according to the preset speed and torque curve, and the load system loads the simulated load in real time according to the test requirements. During the operation, the data acquisition system collects various operating parameters of the gearbox at millisecond intervals and transmits them to the control system. The control system uses a closed-loop control algorithm to adjust the drive and load output in real time to ensure the stability of the test conditions. ​

The video surveillance system synchronously records the gearbox operation screen, and the sealing test system performs a sealing test on the gearbox during a specific test phase. After the test, the data processing software performs a multi-dimensional analysis on the massive amount of data collected to calculate key indicators such as the gearbox's transmission efficiency, vibration spectrum, and sealing performance. The system automatically generates a test report and conducts a comprehensive evaluation and grading of the gearbox performance by comparing it to a standard database. ​

3. 500kW One-to-One Forced air cooling Gearbox and Axle Performance Testing and Reliability Testing Bench Usage Environment and Conditions

• Power supply requirements : 380V±10%, 220V±10% AC power supply, frequency 50Hz±1Hz. Equipped with three-phase isolation transformer and harmonic suppression device to ensure that the harmonic distortion rate of the power grid is less than 5%. At the same time, it is equipped with online UPS uninterruptible power supply, which can provide 30 minutes of emergency power supply guarantee.

• Environmental conditions : The equipment needs to be installed in a constant temperature and humidity laboratory, with an ambient temperature of -10°C to 45°C and a relative humidity of ≤85% . The laboratory floor needs to be vibration-isolated, with a peak vibration acceleration of less than 5m/s². To ensure the heat dissipation needs of the equipment, the laboratory needs to be equipped with a precision air-conditioning system with a cooling capacity of no less than 20kW , and sufficient ventilation space must be reserved.

4. 500kW Gearbox and Axle Performance Testing and Reliability Testing Bench Technical Parameters

SSCD500 - 1500/3800 Electric Dynamometer Technical Parameters

SSCD500 - 300/760 Electric Dynamometer Technical Parameters

5. 500kW Gearbox and Axle Performance Testing and Reliability Testing Bench Reference Standards

QC/T 568-2019 Technical requirements and bench test methods for automotive mechanical transmission assemblies

QC/T-291-2023 "Performance requirements and bench test methods for automotive mechanical transfer case assemblies"

6. 500kW Gearbox and Axle Performance Testing and Reliability Testing Bench Application Areas

• Aerospace field: used for performance testing of precision gearboxes such as aircraft engine reducers and helicopter main reducers to meet reliability verification requirements under extreme conditions such as high temperature, high pressure, and high speed.

• New energy vehicle industry: Adapt to the research and development and testing of new transmission components such as electric vehicle reducers and hybrid transmissions, support electrification and intelligent testing scenarios, and help improve the performance of new energy vehicle power systems.

• High-end equipment manufacturing industry: Serving the gearbox performance testing of CNC machine tools, industrial robots, automated production lines and other equipment to ensure the transmission accuracy and operation stability of high-end equipment.

• Rail transit field: Applied to the performance test of high-speed rail and subway traction gearboxes, simulating complex load conditions during train operation to ensure the safe and reliable operation of rail transit equipment.

• Shipbuilding industry: Performance evaluation of ship propulsion gearboxes and deck machinery gearboxes to meet special working conditions such as high load and strong corrosion in marine environment

​7. ​​Exhibition

From October 24th to October 26th,2024, the Russian International Testing and Control Exhibition was successfully held at the Moscow Klokus Interbational Convention Center. Testing Control is an international testing and control exhibition organized by the renowned Russian exhibition company MVK, which is held anually in Russia.

As the largest and most influential testing and control equipment exhibition in Russia. The exhibition is supported by the Ministry of Defense of the Russian Federation, the Ministry of Industry and Trade of the Russian Federation, the Defense Committee of the State Duma, the Federal Bureau of Technical Regulation and Metrology, and the State Economic Development Bureau. During the three-day exhibition, the exhibition received a total of 10,237 visitors.

Seelong Intelligent Technology (Luoyang) Co.,Ltd. participated in this exhibition and mainly displayed its best-selling products to Russian market, such as engine test benches and transmission test benches. As the only supplier of power system testing equipment in China, Seelong has become a highlight of this exhibition. Visitors from aviation, automobiles, agricultural machinery, power generation equipment and other related fields visited Seelong for communication.

Through this exhibition, Seelong brand awareness in Russia has been strengthened, and it has provided an efficient platform for close communication with Russian partners and customers.

Company Profile

Seelong Intelligent Technology (Luoyang) Co., Ltd. is a high-tech enterprise specializing in equipment measurement, control, design, manufacturing, and sales services for power engineering systems in various fields such as aerospace, automotive, and new energy; The company is located in the beautiful peony city of Luoyang.

Seelong specializes in the research and development, production, and service of testing equipment for new energy motors, hybrid power systems, engines, transmissions, and more. Our main products include electric dynamometers, measurement and control systems, DC power supplies, and working condition guarantee systems. Seelong has a complete sales and service system, adhering to the business philosophy of providing fine quality services for survival and keeping on renovation for development, and providing users with various types of power engineering measurement and control solutions in various fields.

Seelong's advanced design philosophy and rich industry experience give the company a technological Advantages ahead of competitors in the same industry, and the company's products can better meet the actual market demand. Seelong is brave in innovation. While valuing its own technological breakthroughs and development, it has established long-term and in-depth cooperative relationships with multiple domestic research institutions such as Tsinghua University and Shandong University. It has passed CE certification, ISO9001 quality system certification, AAA level enterprise certification, obtained more than ten invention patents, and two software copyrights. It has provided professional equipment and services to more than a hundred users both domestically and internationally, The enterprise has won the trust of domestic and foreign customers with its cost-effective products and high-quality services, and has established a long-term win-win strategic partnership.

The company always adheres to the business philosophy of "taking technological innovation as its mission and quality service as its purpose", constantly surpassing the advanced level in the same industry, integrating into the world, measuring and controlling the future, and creating high-quality products. To provide customers with products and services with high intelligence, precision, speed, reliability, and added value.

All employees of Seelong Intelligent Technology (Luoyang) Co., Ltd. warmly welcome sincere cooperation from domestic and foreign customers, and work together for the future and common development.

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FAQ

Q: What's the minimum order quantity for our cooperation?
A: We support small trail order of 1 pcs for stock products.
Q:How can I learn more about the products?
A: Please leave your email and we will send you your electronic sample book.
Q: What's your payment term?
A: Normally 40% T/T deposit, pay in full before shipment.
Q:What's the lead time for my orders?
A: Dynamometers production cycle is 6-8 weeks, sensors production cycle is 2-3 weeks, other products please contact with us.
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A: Leave us your email, our technical staff will communicate with you about the detailed plan.
Q: Can I come to visit your factory?
A: Sure, you are always welcomed to have a visit.