Sichuan Chengbang Haoran Measurement and Control Technology Co., Ltd.
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GT4000 -- Helicopter Reducer Test System

The helicopter reducer plays the role of matching speed and transferring torque between the prime mover and the working machine or actuator. It is widely used in modern machinery. According to JB/ T9050.3-1999 cylindrical gear reducer loading test method and referring to other national standard requirements and various assembly test standards, this system carries out type verification test for transmission system test purpose, test procedure and test method.

Case Presentation

GT4000 - Helicopter Reducer Test System - Product background

Summary:

The helicopter reducer plays the role of matching speed and transferring torque between the prime mover and the working machine or actuator. It is widely used in modern machinery. According to JB/ T9050.3-1999 cylindrical gear reducer loading test method and referring to other national standard requirements and various assembly test standards, this system carries out type verification test for transmission system test purpose, test procedure and test method.

Bench pictures

Reference standards:

L QC/T 568-1999 Test methods for automotive mechanical transmission stands

L JB/T 9720-1999 Automotive Transmission Test standard

Mechanical safety protection Design and manufacturing requirements for fixed and movable protection devices

L GB/T 4793.1-2016 Safety requirements for electrical equipment used in measurement, control and laboratories - General requirements

L GB/T 50055-2011 General electric equipment distribution design specification

Mechanical and electrical safety mechanical and electrical equipment -- Part 1: General technical conditions

L According to national, local, industrial, demander enterprise technology, safety, environmental protection regulations and standards

L Safety protection shall be in accordance with the Production Safety Law of China and relevant laws and regulations;

GT4000 -- Helicopter Reducer Test System -- Topology

Topology diagram

GT4000 -- Helicopter gear reducer test system is modular, integrated design, operation part is ergonomic design, can complete manual/automatic mode control. It is composed of mechanical system, driving system, loading system, guarantee system, electrical system and upper computer software system.

L Mechanical system: cast iron platform, bearing housing, drive system mechanical connection device, load system mechanical connection device, shafting connection part and other equipment composition.

L drive system: high speed and low inertia drive motor, torque and speed measuring device.

L Loading system: low speed and high torque loading dynamometer, torque and speed measuring device.

L Guarantee system: gear box temperature control system and other equipment composition.

Electrical system: drive, load controller, real-time data acquisition system, data acquisition, alarm system and other equipment composition.

L Software system: Upper computer test software is divided into data acquisition and communication module, data acquisition and setting module, data real-time exchange and control module, and data processing module. By the upper computer according to the test project to complete the test control, data analysis and display, data record and export and other functions.

GT4000 - Helicopter Reducer Test System - System functions

Basic range and accuracy:

● Driving recommended power range: 0~500KW power level, support other other power, speed, torque level customization;

● Driving speed measurement range: 0~3000r/min;

● Driving torque measurement range: 0~3000N. M;

● Recommended power range for load: 0~500KW power level, supporting other customization of power, speed, torque level;

● Load speed measurement range: 0~2000r/min;

● Load torque measurement range: 0~10000N.m;

Experimental items:

Transmission without load loss, transmission transmission efficiency, transmission contact spots, transmission gear fatigue strength durability, high load sintering transformer box

Inspection, gearbox high-temperature sintering test, gearbox low-temperature sintering test, gearbox dynamic sealing test, transmission vibration test, clutch combination speed test, clutch transmission torque test, clutch repeated combination test oil pressure, abnormal sound confirmation, running-in, etc.

GT4000 - Helicopter Reducer Test System - Key features

01 Structural Design

The load motor is installed vertically to simulate the resistance of aircraft propeller blades. The reducer is installed at the bottom of the frame. The front-end drive is driven by high-dynamic motor to simulate the actual condition test of the entire helicopter reducer.

02 Advanced means of measurement

Advanced real-time measurement and control system is adopted, including input electrical parameters test, rotational speed torque test, etc. The sampling rate of torque and rotational speed is up to 1000Hz, which meets the requirements of high precision and rapid response of the test system. Moreover, transient data and eigenvalue data are provided to facilitate the comprehensive analysis of test process data by software in the later stage.

The test items are complete

According to the test requirements stipulated by national standards, the test items can be increased or decreased according to the configuration module, which can meet the test items for various types of tests

04 Driving system

With low inertia asynchronous motor/permanent magnet synchronous motor as the driver input system, improve the system dynamic response of torque and rotational speed and provides the measurement range and precision, improve driving performance (positive/reverse), and shorten the response time of load, which can realize arbitrary load curve of load, high simulation speed reducer input of real-time operation condition.

05 Loading system

High torque and low speed dynamometer are adopted as the system load. According to the characteristics of the tested parts, high-precision torque and speed sensors are adopted to improve the data dynamic response adoption rate. Vector /DTC mode is adopted to load the system, which can be loaded according to the required high-speed dynamic loading characteristics, thus highly simulating the real-time operation condition of transmission output.

06 Humanized design

Adopt professional gearbox test bench, fixture has fast clamping function, and convenient loading and unloading, can adapt to different gearbox installation, system operation recommended to use the cabinet + computer desk control mode, can complete the unit set complete all test operation layout.

08 Customized test software

The test system test software developed by Sichuan Chengbang software research and development team categorizes the software interface and process according to the national standard test items to reduce repeated tests and greatly improve the work efficiency of test personnel. It also has the functions of real-time curve drawing, transient value capture, trend curve drawing and analysis, multi-parameter combination display, qualification determination, report export and so on.

GT4000 - Helicopter Reducer Test System - Major applications

L Helicopter reducer and 90° Angle reducer test

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