| Quantity: | |
|---|---|
JKT durability reducer test bench is designed to meet the testing requirements of various automotive transmissions. It can accurately simulate the actual driving conditions of vehicles and various real world operating conditions of the unit under test (UUT). It supports comprehensive tests including steady-state/dynamic performance, durability, NVH, transmission efficiency, shifting performance, and reliability & durability under extreme environments. Key parameters such as torque, speed, efficiency and temperature rise can be measured precisely to identify potential design flaws and performance bottlenecks in advance, avoid safety risks and economic losses, and improve testing accuracy.
The JKT durability reducer test bench is equipped with a precise and reliable mechanical system, a highly dynamic and stable control system, and powerful software packages.
JKT provides customers with both transverse and longitudinal transmission test benches, which can be applied to various vehicles such as passenger cars, commercial vehicles, heavy-duty trucks and off-road machinery. The transverse transmission test bench features an extremely small wheel center distance, making it suitable for testing extremely compact transmissions in battery electric vehicles and hybrid vehicles. JKT has designed a test bench that can handle both coaxial reducer testing and conventional reducer testing, based on the characteristics of coaxial reducers and general reducers.
Depending on the type of gearbox or reducer, we provide different types of drive motors and load motors. The drive motor for the transverse gearbox test bench is compact in size, typically adopting a small high-speed PM motor.
Drive Motor Parameters for Transverse Transmission / Reducer Test Bench:
Type | nmax(rpm) | Tr(N.m) | Pr(kW) | nr(rpm) | n2(rpm) | Pmax(kW)@ nmax | Cooling |
HMD-A250-10 | 10000 | 400 | 250 | 5968.7 | 10000 | 250 | Fluid |
HMD-B300-16 | 16000 | 400 | 300 | 7162.5 | 16000 | 300 | Fluid |
HMD-B400-20 | 20000 | 500 | 400 | 7640 | 20000 | 400 | Fluid |
HMD-B500-20 | 20000 | 1000 | 500 | 4775 | 20000 | 500 | Fluid |
HMD-B500-25 | 25000 | 500 | 400 | 7640 | 25000 | 400 | Fluid |
Drive Motor Parameters for Longitudinal Gearbox / Reducer Test Bench:
Type | nmax(rpm) | Tr(N.m) | Pr(kW) | nr(rpm) | n2(rpm) | Pmax(kW)@ nmax | Cooling |
HMD-A250-10 | 10000 | 800 | 250 | 2984 | 10000 | 250 | Fan |
HMD-B500-20 | 20000 | 1000 | 500 | 4775 | 20000 | 500 | Fluid |
HMD-C400-12 | 12000 | 1200 | 400 | 3183 | 12000 | 300 | Fan |
HMD-C400-10 | 10000 | 2000 | 400 | 1910 | 7500 | 300 | Fan |
HMD-C350-09 | 8000 | 3000 | 350 | 1114 | 7000 | 300 | Fan |
HMD-C350-07 | 7000 | 2000 | 350 | 1671 | 6000 | 300 | Fan |
Load Motor Parameters for Transmission / Reducer Test Bench:
Type | nmax(rpm) | Tr(N.m) | Pr(kW) | nr(rpm) | n2(rpm) | Pmax(kW)@ nmax | Cooling |
LMD-A300-03 | 3000 | 3000 | 300 | 955 | 3000 | 300 | Fan |
LMD-B500-20 | 3000 | 4000 | 300 | 800 | 3000 | 300 | Fan |
LMD-C300-12 | 3000 | 5000 | 400 | 761 | 3000 | 400 | Fan |
LMD-C300-10 | 3000 | 6000 | 500 | 796 | 3000 | 500 | Fan |
LMD-C350-09 | 3000 | 10000 | 500 | 477.5 | 2000 | 400 | Fan |
LMD-C350-07 | 2000 | 15000 | 500 | 318 | 1500 | 400 | Fan |
LMD-C350-07 | 1500 | 20000 | 600 | 286.5 | 1000 | 400 | Fan |
Note: Environmental chambers are optional for transmission or reducer test benches.
JKT can provide customized products according to customer requirements.
(1) Torque measurement control accuracy：±0.05%FS
(2) Speed sensor pulse resolution：1024/600pprppr
(3) Torque control accuracy：±(0.5~1)%FS
(4) Speed control accuracy：±(0.01~0.05)%FS
(5) The max vibration value of dynamometer（RSM）：≤2mm/s（no load）
(6) The bearing support temperature rise：≤35℃
(7) The max vibration value of the bearing support（RSM）：≤2mm/s（no load）
(8) DAQ sampling rate：1kHz
(9) Current measurement channel:4/6
(10) Voltage measurement channel:4/6
(11) Measurement accuracy of power analyzer: ±0.05%
(12) Temperature sensor measuring range: -50℃~200℃
(13) Measurement accuracy of temperature sensor: A class
(14) Vibration sensor measuring range: 0~20mm/s
Main test contents:
(1) Efficiency test
(2) Torque test
(3) Speed test
(4) Differential test
(5) Temperature rise test
(6) Over-load test
(7) Steady-state test
(8) Maximum speed test
(9) Durability with temperature climate test
(10) CLTC/WLTC cycle condition test
(11) User-defined cycle condition test
(12) Controller calibration test
(13) Road load simulation test
(14) Accelerated response test
(15) Torque response test
(16) NVH test (option)
Basic configurations:
Dynamometer & Mechanical System: A high-dynamic synchronous motor is selected as the drive motor, and two asynchronous motors is selected as the load motors, equipped with a high-speed drive shaft system and precision, reliable mechanical components. Each load unit can be moved along the axis and height direction.
Frequency Converter: Four-quadrant frequency converters are adopted for dynamic or steady-state control of the dynamometer. It enables control of rotational speed, torque, allowing the dynamometer to operate in either motoring or generating mode.
MCU Power Supply: Provides an adjustable low-voltage power supply for the motor controller.
Test Object Cooling System: Supplies cooling medium for the tested motor and controller. An oil cooling system is available for certain oil-cooled test pieces. Parameters including temperature, pressure and flow rate of the cooling system are fully adjustable.
Climate Chamber: Provides a simulated operating environment with controllable high/low temperature and humidity for the test objects.
Automated Measurement & Control System: Conducts overall control and condition monitoring of the entire motor test bench.
High speed Reducer test bench
Drive motor—400kW 500N.m 25000rpm
Load motor—400kW 5000N.m 3000rpm
High speed Coaxial Reducer test bench
Drive motor—400kW 500N.m 25000rpm
Load motor—400kW 5000N.m 3000rpm
JKT has design test benches for hybrid transmissions. The test bench consists of two high-speed input dynamometers and two wheel-side loading motors. The high-speed input dynamometer units support height and horizontal radial adjustment, while the wheel-side loading motor units allow axial and height adjustment.
Hybrid powertrain test bench
Drive motor—300kW 500N.m 20000rpm
Load motor—250kW 3000N.m 3000rpm
JKT has designed a dedicated test bench capable of testing hybrid transmissions, conventional reducers, and coaxial reducers. The test bench consists of two high-speed input dynamometers and two wheel-side loading motors. The high-speed input dynamometer units support height and horizontal radial adjustment, while the wheel-side loading motor units allow axial and height adjustment. One high-speed input dynamometer is connected to a high-speed gearbox with a hollow output shaft, which is used to connect the wheel-side loading motor with the output shaft of the coaxial reducer.
Drive motor1—300kW 500N.m 20000rpm
Drive motor2—400kW 1000N.m 16000rpm
Load motor—400kW 5000N.m 3000rpm
Q 1: What types of reducers can this durability test bench test?
A1：This durability reducer test bench is developed specifically for the new energy vehicle industry. It can conduct full-condition durability tests on reducers and vehicle transmission assemblies matched with battery electric vehicles and hybrid electric vehicles. It also supports lifespan, fatigue and long-term reliability verification of reduction mechanisms for passenger and commercial vehicles, covering the full R&D testing process in the early stage of vehicle development.
Q 2: What core benefits can automotive manufacturers gain from this test bench?
A2：Comprehensive bench verification of vehicle transmissions and reducers can be completed at the early R&D stage to eliminate failure risks of gears, bearings and seals under long-term operation in advance. It greatly shortens the vehicle development cycle, cuts the cost of troubleshooting during real vehicle road tests, and improves the reliability of mass-produced matched reducers.
Q 3: What real driving conditions can the bench simulate for durability testing?
A3：The equipment can accurately simulate full-road load conditions including vehicle start-up, acceleration, climbing, high-speed cruising and frequent start-stop. It can stably simulate alternating loads of high/low torque and variable speed for long-term operation, continuously collect core durability data such as vibration, temperature rise, transmission efficiency and component wear, and highly restore the real on-board operating environment of reducers.
Q 4: Is customized service available for different reducer models? What about delivery and after-sales support?
A4：Non-standard customization is supported. The bench tooling, drive and loading modules can be adjusted according to the torque, rotational speed and installation dimensions of customers’ test reducers. Complete joint debugging and inspection will be carried out before delivery. We provide on-site installation & commissioning, operator training, on-site maintenance within the warranty period and lifelong technical upgrade services.
