Design of a mechanically closed-loop test rig for testing aviation industry’s gearboxes

Abstract

Due to the wide usage of rotary equipment and the necessity of their testing for maintenance and repair, test rigs have become necessary. The mechanical closed-loop test rig developed in Sharif University of Technology branch of ACECR (Academic Centre of Education, Culture and Research) is a test rig with low energy losses that is suitable for testing high power gearboxes such as aerospace or wind turbine gearboxes. It can be loaded up to 489Hp at a maximum speed of 3000 rpm, and the test components can be tested in different testing conditions including a variety of torques and speeds. This paper describes the preliminary, conceptual, and detailed design, steps including frame work design, control system design, hydraulic system and torque generator design asn well as a dynamic and static analysis of the whole system. Also a simplified model of the system is presented and qualified, and some data of test rig’s working conditions is presented. These data includes the temperature change of the gearboxes, their vibration in time, and also the variation of torque, hydraulic pressure, and motor speed. Furthermore, the relation between these parameters is investigated to determine the behaviour of the system. The validity of the system’s dynamic modelling is also investigated and verified.

Keywords:

• closed-loop test rig
• gearbox test
• mechanical energy regeneration
• mechanically closed-loop
• aviation gearbox test
• power regeneration test rig

Additional information

Notes on contributors

Shadan Mozafari

Shadan MOZAFARI, Msc, Mechanical Eng.

Education: 2012–2014, Bachelor of Mechanical Engineering,

AmirKabir University of Technology; 2014–2016, Master of Mechanical Engineering, Sharif University of Technology.

Research interests: power transmission systems, vibration, and machining. Present position: 2015–2016, researcher, Sharif University Branch of ACECR.

Mehdi Rezazadeh Mohamadi

Mehdi REZAZADEH, Msc, Mechanical Eng.

Education: 2004–2008, Bachelor of Mechanical Engineering,

Isfahan University of Technology;

2008–2011, Master’s degree in Mechanical Engineering, Iran University Science and Technology.

Research interests: transmission technology, automation, 3D printing, and metal forming. Publications: author of 2 Articles, over 5 conference papers, and 3 technical industry reports.

Present Position: since 2016, Mechanical Engineer in the ACECR Group.

Somaye Dolatkhah Takloo

Somayeh DOLATKHAH TAKLOO, Msc. Electrical Eng.

Education: 2001–2006, Bachelor of Electronics Engineering; 2007–2010,

Master of Control Engineering, AmirKabir University of Technology (Tehran Polytechnic). Research interests: nonlinear system control, aircraft. system control, and disturbance observing in aviation systems.

Publication: author of 5 conference papers and 2 articles.

Present position: 2014–2016, researcher in the ACECR (Academic Centre of Education, Culture and Research).

Mohsen Mardani

Mohsen MARDANI, Assistant Professor

Education: 2000–2005, Bachelor of Electrical Engineering; 2005–2013, Master and PhD degrees, AmirKabir University of Technology; since 2013, research assistant,

Nanyang Technological University, Singapore. Research interest: test systems.

Publications: author of 20 papers, 2 books, and 16 technical industry reports.

Present positions: since 2015, Vice president of Research and Technology, Sharif University Branch of ACECR.