Field of Research
Test Rigs


Test Rigs of the Group Gear Testing

Universal Test Rig

Transmission test rigs enable durability testing of components and the research of the excitation and noise behavior of transmissions and their components. The universal gear test rig at WZL consists of three electric engines which are designed for a 4-quadrant operation. The generators are partly adjustable in height and can be moved freely in longitudinal and transverse direction on a large clamping area. Therefore the configuration can be changed according to the test at hand. The universal gear test rig enables the accomplishment of a wide range of measurements and tests on transmissions and their components. In addition to sound pressure and structure borne noise, transmission error and angular acceleration can be detected using flexible measurement units at user defined positions. For acoustical tests the universal test rig is equipped with a certified acoustic booth.

Universal Test Rig (.pdf)

Electrical Power Circle Test Rig

Noise is one important quality criterion for gears and transmissions. The noise excitation of gear sets can be tested by single flank and noise testing. Also the contact pattern is a quality criterion for gear sets. WZL has developed different test fixtures to investigate the excitation behavior of gear sets. These test fixtures enable gear tests under constant conditions.
In a standard transmission the housing, bearings, tolerances and deflections under load have an influence on the noise excitation. With WZLs test fixtures it is possible to test gear sets without the influences of a real transmission.
Gears with various geometries can be tested on the test rig. Manual transmissions are used to transmit the drive torque to higher load ranges. The maximum attainable rotational speeds are correspondingly reduced. The test cells themselves consist of two separate bearing housings which contain the sensors necessary for measuring the rotational acceleration and transmission error. The sound pressure is measured in the near field using a microphone. Acceleration sensors are used for recording of the structure borne noise.

Electrical Power Circle Test Rig (.pdf)

Bevel Gear Tester

For the investigation of bevel and hypoid gearings an Oerlikon Geartec bevel gear tester is available at WZL. In addition to the classic single flank working test, the Spiromatik T20 also permits measurement at operationally relevant speeds of up to n = 3000 min-1.

Bevel Gear Tester (.pdf)

Roller Test Rigs

Due to the cost-intencive production of test gears with their complex geometry a competitive and time-saving analogy method with which the tribological conditions can be tested is required. At the WZL this analogy test is performed on roller test rigs (two disc test rigs) using cylindrical and crowned rollers. A well-defined hertzian pressure is applied in the rolling contact using a hydraulically powered piston. The WZL is equipped with six roller test rigs to perform test concerning load carrying capacity in the roller contact. In addition to those test rigs a test rig with extended measurement equipment is available which can test the coefficient of friction or the lubrication conditions in the roller contact.

Roller Test Rigs (.pdf)

Back-to-back Test Rigs

With these test rigs the influence of the material, the gear geometry or the lubrication on the tooth flank load carrying capacity is tested. The best-known back-to-back test rig is the one according to DIN 51354. The WZL owns 16 back-to-back test rigs according to DIN 51354 with center distances of a = 91,5 mm, a = 112,5 mm and a = 200 mm.
In addition to the test rigs with a fixed center distance the WZL offers three 3-shaft power circle test rigs with variable center distances. With this test rig two gears mesh with one pinion. By adjusting the direction of twist and propulsion it is possible to have the pinion or the gears as the driving component. The center distance can be varied between 66 mm < a < 120 mm. In addition to the unidirectional 3-shaft test rigs the WZl has a 3-shaft test rig where reverse bending can be tested.

Back-to-back Test Rigs (.pdf)
Reverse Bending Test Rigs (.pdf)

Pulsator Test Rigs
To test the tooth root load carrying capacity pulsators are used as an analogy test method. This method offers a cost-saving alternative to known back-to-back test rig solutions. The WZl is equipped with three pulsators. A hydraulic pulsator by Instron is capable of producing a force of up to F = 250 kN and frequencies of up to f = 100 Hz. The other pulsator test rigs were made by Schenck and use the principle of resonance to apply the force. They are capable of applying a force of up to F = 60 and F = 200 kN respectively.

Pulsator Test Rigs (.pdf)



Do you have questions concerning this research area?

Your contact:
Dieter Mevissen, M.Sc.
Workgroup Leader
Manfred-Weck-Haus 107
Tel.: +49 241 80-27560
Fax: +49 241 80-22293


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