FIELD
The present disclosure relates to the field of test rigs for testing power generation or
transmission components.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to hav5 e
the meaning as set forth below, except to the extent that the context in which they are
used indicate otherwise.
Fluid – The „fluid‟ hereinafter in the specification includes only a liquid medium or a
liquid and gaseous medium or a medium having liquid, gas and solid particles,
10 wherein the solid particles include organic and inorganic particles.
BACKGROUND
The background information herein below relates to the present disclosure but is not
necessarily prior art.
Conventionally, a test rig having a water pump is used to evaluate performance of a
15 power generation or transmission component such as an engine or gearbox. In such
test rigs, a water pump is connected to a component to be tested. The water pump is
driven by the output power generated by the component. The water pump draws
water from a water reservoir and delivers it at higher pressure. The speed of the water
pump and increase in water pressure are directly proportional to the output power of
20 the component. Thus, by measuring fluid properties, like pressure and/or flow rate, of
water exiting the water pump, the performance of the component is evaluated.
The conventional water based test rigs include a heat exchanger to cool hot water
delivered by the pump. A cold fluid, typically cold water, is used to cool the hot
water delivered by the pump. The conventional test rig includes a separate cooling
3
system for cooling the hot water in the heat exchanger. The components of the
cooling system, for example, a pump and a cooler, are typically operated using
electrical power. Thus, the conventional test rigs can be installed where the electrical
supply is readily available. This limits mobility of the test rigs. Further, such test rigs
do not facilitate performance evaluation during testing itself. The component to 5 be
tested is typically operated for more than 500 hours. During testing, if there is failure
or malfunctioning of any part of the component, the component does not provide
rated power output. However, in the conventional test rigs, such failure can only be
detected once the test is completed. In such case, lot of time is wasted and
10 performance of the component cannot be accurately evaluated. The conventional test
rigs are inconsistent in operation, and fluctuations are observed in pressure or flow
measurements of water delivered by the water pump of the conventional test rigs.
Further, the conventional test rigs are not robust.
Therefore, there is felt a need of a test rig that alleviates the abovementioned
15 drawbacks of conventional test rigs, and facilitates accurate performance evaluation
of a power generation or transmission component.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein
satisfies, are as follows:
20 An object of the present disclosure is to provide a regenerative test rig for testing a
power generation or transmission component.
Another object of the present disclosure is to provide a regenerative test rig that
eliminates need of an external power source.
Yet another object of the present disclosure is to provide a regenerative test rig that
25 has reduced footprint as compared to conventional test rigs.
4
Yet another object of the present disclosure is to provide a regenerative test rig that
facilitates performance evaluation of a component during testing.
Yet another object of the present disclosure is to provide a regenerative test rig that is
durable.
Yet another object of the present disclosure is to provide a regenerative test rig 5 that is
portable.
Other objects and advantages of the present disclosure will be more apparent from the
following description, which is not intended to limit the scope of the present
disclosure.
10 SUMMARY
The present disclosure envisages a regenerative test rig for testing a power generation
or transmission component. The regenerative test rig comprises an oil reservoir, a
first pump, means to couple the first pump to the power generation or transmission
component, a fluid reservoir, a second pump, a first hydraulic motor, a heat
15 exchanger, a flow meter, and optionally a pressure gauge. The first pump is in fluid
communication with the oil reservoir. The second pump is in fluid communication
with the fluid reservoir. The first hydraulic motor is actuated by oil delivered by the
first pump, and is configured to operate the second pump. The heat exchanger is in
fluid communication with the first pump and the fluid reservoir to receive a cold fluid
20 from the fluid reservoir and oil from the first pump to facilitate heat transfer
therebetween. The flow meter is configured to measure flow of oil flowing through
the test rig in an operative configuration of the test rig. The pressure gauge measures
pressure generated during the operation of the first pump in an operative
configuration of the test rig. In an embodiment, the test rig includes both the flow
25 meter and the pressure gauge.
5
The test rig comprises a cooler in fluid communication with the second pump, and is
configured to reduce temperature of fluid received therein. The cooler is operated by
a second hydraulic motor which is actuated by the oil received from the first pump.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A regenerative test rig for testing a power generation or transmission component, 5 of
the present disclosure, will now be described with the help of the accompanying
drawing, in which:
Figure 1 illustrates a block diagram depicting a regenerative test rig, in accordance
with an embodiment of the present disclosure; and
10 Figure 2 illustrates a block diagram depicting the regenerative test rig, in accordance
with another embodiment of the present disclosure.
LIST OF REFERENCE NUMERALS
100 – Test rig
110 – Oil reservoir
15 120 – First pump
130 – Power generation or transmission component
135 – Auxiliary power source
138 – Means
140 – Pressure gauge
20 150 – Pressure relief valve
6
160 – Heat exchanger
170 – Flow meter
180 – Safety valve
190 – Flow control valve
210 – Fluid rese5 rvoir
220 – Second pump
222 – First hydraulic motor
230 – Cooler
232 – Second hydraulic motor
10 DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the
accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the
present disclosure to the person skilled in the art. Numerous details, are set forth,
15 relating to specific components, and methods, to provide a complete understanding of
embodiments of the present disclosure. It will be apparent to the person skilled in the
art that the details provided in the embodiments should not be construed to limit the
scope of the present disclosure. In some embodiments, well-known processes, wellknown
apparatus structures, and well-known techniques are not described in detail.
20 The terminology used, in the present disclosure, is only for the purpose of explaining
a particular embodiment and such terminology shall not be considered to limit the
scope of the present disclosure. As used in the present disclosure, the forms "a”, "an",
7
and "the" may be intended to include the plural forms as well, unless the context
clearly suggests otherwise. The terms "comprises", "comprising", “including”, and
“having” are open ended transitional phrases and therefore specify the presence of
stated features, integers, steps, operations, elements, modules, units and/or
components, but do not forbid the presence or addition of one or more other feature5 s,
integers, steps, operations, elements, components, and/or groups thereof. The
particular order of steps disclosed in the method and process of the present disclosure
is not to be construed as necessarily requiring their performance as described or
illustrated. It is also to be understood that additional or alternative steps may be
10 employed.
When an element is referred to as being "mounted on", “engaged to”, "connected to",
or "coupled to" another element, it may be directly on, engaged, connected or coupled
to the other element. As used herein, the term "and/or" includes any and all
combinations of one or more of the associated listed elements.
15 The terms first, second, third, etc., should not be construed to limit the scope of the
present disclosure as the aforementioned terms may be only used to distinguish one
element, component, region, layer or section from another component, region, layer
or section. Terms such as first, second, third etc., when used herein do not imply a
specific sequence or order unless clearly suggested by the present disclosure.
20 Terms such as “inner”, “outer”, "beneath", "below", "lower", "above", "upper", and
the like, may be used in the present disclosure to describe relationships between
different elements as depicted from the figures.
The present disclosure envisages a regenerative test rig (hereinafter also referred to as
„test rig‟) for testing a power generation or transmission component.
25 The test rig, of the present disclosure, is now described with reference to Figure 1 and
Figure 2. Figure 1 illustrates a block diagram depicting a test rig 100 in accordance
8
with an embodiment of the present disclosure. Figure 2 illustrates a block diagram
depicting the test rig 100 in accordance with another embodiment of the present
disclosure.
The test rig 100 comprises an oil reservoir 110, a first pump 120, optionally a
pressure gauge 140, a pressure relief valve 150, a heat exchanger 160, a flow mete5 r
170, a safety valve 180, a flow control valve 190, a fluid reservoir 210, a second
pump 220, a first hydraulic motor 222, a cooler 230, and a second hydraulic motor
232.
The oil reservoir 110 stores oil therewithin. The capacity of the oil reservoir 110
10 varies as per the application. In one embodiment, the oil reservoir 110 has 120 liters
oil storage capacity.
The first pump 120 is in fluid communication with the oil reservoir 110 via a first
conduit (not specifically shown in figures). The first pump 120 can be of any suitable
type as per application requirements. In one embodiment, the first pump 120 is a vane
15 pump. In another embodiment, the first pump 120 has capacity to deliver fluid at a
rate of 115 cm3/revolution.
The test rig 100 further includes means 138 configured to couple the first pump 120
to a power generation or transmission component 130 to be tested. The means 138
can include a connecting shaft or any other suitable arrangement for connecting the
20 first pump 120 to the component 130. The first pump 120 is operated using the output
power generated by the component 130.
In an embodiment, the power generation or transmission component 130 can be an
internal combustion engine or a gearbox.
In an embodiment, the first pump 120 is driven by the component 130 alone as shown
25 in Figure 1. In other embodiment, the first pump 120 is coupled to the component 130
as well as an auxiliary power source 135, as shown in Figure 2. The auxiliary power
9
source 135 can be an electric motor, a hydraulic motor, or any other suitable power
source coupled to the first pump 120 for driving the first pump 120. The advantage of
providing the auxiliary power source is that, before initiating testing, the first pump
120 is operated using the auxiliary power source 135. Thus, when the testing is
initiated, the readings of the parameters related to the performance of the first 5 st pump
120 can be taken immediately. More specifically, the initial frictional force or torque
requirement can be fulfilled by the auxiliary power source 135, and then the
component 130 to be tested can be connected to the first pump 120 for evaluating its
performance. This avoids errors in the readings of the parameters.
10 The second pump 220 is in fluid communication with the fluid reservoir 210. When
actuated, the second pump 220 is configured to draw the fluid contained within the
fluid reservoir 210. The first hydraulic motor 222 is actuated by the oil delivered by
the first pump 120, and is configured to operate the second pump 220. More
specifically, the first hydraulic motor 222 is in fluid communication with an outlet of
15 the first pump 120 and receives pressurized oil from the first pump 120. The first
hydraulic motor 222 is actuated by the pressurized oil. The first hydraulic motor 222
is coupled to the second pump 220.
The heat exchanger 160 is in fluid communication with the first pump 120 and the
fluid reservoir 210 to receive oil and the cold fluid respectively to facilitate heat
20 transfer therebetween. More specifically, the heat exchanger 160 reduces the
temperature of hot oil received therein by facilitating heat transfer between the oil and
the cold fluid.
The heat exchanger 160 is configured to receive oil delivered by the first pump 120
and a cold fluid from said fluid reservoir 210 to facilitate heat transfer therebetween.
25 In the heat exchanger 160, oil transfers heat to the cold fluid to become a cold oil.
The cold oil is then transferred to the oil reservoir 110. The cold oil received in the oil
reservoir 110 is now available for recirculation through the first pump 120. The test
10
rig 100 includes a second conduit (not specifically shown in figures) connected to the
heat exchanger 160 and the oil reservoir 110, and configured to convey oil from the
heat exchanger 160 to the oil reservoir 110.
The flow meter 170 is configured to measure flow of oil flowing through the test rig
100 in an operative configuration of the test rig 100. The flow meter 170 can b5 e
suitably arranged in the test rig 100 such that the flow meter 170 accurately measures
the flow rate of oil flowing through the test rig 100.
In an embodiment, the flow meter 170 is connected between the heat exchanger 160
and the oil reservoir 110 as shown in Figure 1 and Figure 2. More specifically, the
10 flow meter 170 measures the flow rate of oil exiting the heat exchanger 160, which
was fed by the first pump 120.
The pressure gauge 140 is configured to measure pressure generated during the
operation of the first pump 120 in an operative configuration of the test rig 100. The
pressure gauge 140 is arranged in the test rig 100 such that the pressure gauge 140
15 measures the pressure of the oil immediately after exiting the first pump 120.
In one embodiment, the test rig 100 includes the flow meter 170. In another
embodiment, the test rig 100 includes both the flow meter 170 and the pressure gauge
140.
Further, the cooler 230 is in fluid communication with the second pump 220, and
20 configured to reduce temperature of fluid received therein. The cooler 230 can be
suitably arranged in the test rig 100.
In an embodiment, the cooler 230 is arranged between the second pump 220 and the
heat exchanger 160. More specifically, an inlet of the cooler 230 is in fluid
communication with an outlet of the second pump 220 to receive hot fluid therefrom.
25 The hot fluid is then cooled in the cooler 230. Further, an outlet of the cooler 230 is in
fluid communication with an inlet of the heat exchanger 160 to convey cold fluid to
11
the heat exchanger 160. In this embodiment, the cooler 230 receives hot fluid from
the second pump 220. The hot fluid is cooled in the cooler 230, and the cold fluid is
then conveyed to the heat exchanger 160. In the heat exchanger 160, the temperature
of hot oil is reduced using the cold fluid. Due to heat transfer, the temperature of cold
fluid increases and the cold fluid becomes the hot fluid. The hot fluid is 5 then
conveyed to the fluid reservoir 210, which is then conveyed to the cooler 230 via the
second pump 220.
In another embodiment, the cooler 230 is arranged between the heat exchanger 160
and the fluid reservoir 210. More specifically, the inlet of the cooler 230 is in fluid
10 communication with an outlet of the heat exchanger 160, and the outlet of the cooler
230 is in fluid communication with an inlet of the fluid reservoir 210. In this
embodiment, the hot fluid exiting the heat exchanger 160 is cooled in the cooler 230,
and then conveyed to the fluid reservoir 210. The cold fluid in the fluid reservoir 210
is then conveyed to the heat exchanger 160 using the second pump 220.
15 The cooler 230 can be any type of heat exchangers known in the art. In an
embodiment, the cooler 230 is an air cooler/radiator. The cooler 230 includes a fan.
The fan is configured to reduce the temperature of the fluid received in the cooler,
thereby cooling it. The second hydraulic motor 232 is coupled to the fan for driving
the fan. The second hydraulic motor 232 is operated by the pressurized oil received
20 from the first pump 120.
Further, an inlet of the second hydraulic motor 232 is in fluid communication with
the first pump 120, and an outlet of the second hydraulic motor 232 is in fluid
communication with the inlet of the heat exchanger 160. Thus, the heat exchanger
160 receives hot oil from two sources, i.e., from the outlet of the first hydraulic motor
25 222 and from the outlet of the second hydraulic motor 232.
Further, the pressure relief valve 150 is configured to receive oil from the first pump
120. Further, the pressure relief valve 150 is configured to allow oil flow to the first
12
hydraulic motor 222 and second hydraulic motor 232, through the flow control valve
190, when oil pressure generated by said first pump 120 exceeds a preset pressure
value. The preset pressure value is determined as per the load requirement. Thus, the
first hydraulic motor 222, the second hydraulic motor 232, and the cooler 230 receive
pressurized oil from the first pump 120 via the pressure relief valve 150 for 5 their
operation.
Further, the flow control valve 190, which is disposed between the pressure relief
valve 150 and the first hydraulic motor 222 and the second hydraulic motor 232, is
configured to split and thereby regulate the flow of the fluid received from the first
10 pump 120 (through the pressure relief valve 150) and flowing to the first hydraulic
motor 222 and the second hydraulic motor 232. By regulating the flow of the fluid
flowing to the first hydraulic motor 222 and the second hydraulic motor 232, their
respective speeds of rotation (RPM) is regulated by considering the load driven by
each of the hydraulic motors 222 and 232. Thereby, the thermal efficiency of the test
15 rig in general is optimized.
In an embodiment, the pressure gauge 140 is arranged between the first pump 120
and the pressure relief valve 150, and measures pressure of oil immediately after
exiting the first pump 120.
The safety valve 180 is connected between the first pump 120 and the oil reservoir
20 110. The safety valve 180 releases excess oil pressure generated by the first pump
120.
The working of the test rig 100 is now elaborated in subsequent paragraph.
Initially, an output shaft of the component 130 to be tested is coupled to the first
pump 120. The first pump 120 is driven by the output power generated by the
25 component 130. As the component 130 is actuated, the first pump 120 draws oil from
the oil reservoir 110. The pressure and flow rate of oil exiting the first pump 120 are
13
directly proportional to the power generated by the component 130. Once the oil exits
the first pump 120 and flows through the test rig 100, the pressure and flow rate of
the oil are measured using the pressure gauge 140 and the flow meter 170
respectively. Using mathematical equations relating the pressure and flow rate of oil
to the power imparted on the pump, the performance of the pump can be evaluate5 d.
Further, by knowing transmission efficiency between the component 130 and the first
pump 120, the performance of the component 130, for example, in terms of torque
and output power, can be evaluated.
The oil exiting the first pump 120 is received in the pressure relief valve 150. Once
10 the oil pressure reaches the set value, the pressure relief valve 150 conveys the oil to
the first hydraulic motor 222 and the second hydraulic motor 232. Further, the oil
exiting the first hydraulic motor 222 and the second hydraulic motor 232 is conveyed
to the heat exchanger 160 via a third and fourth conduits (not specifically shown in
figures). The hot oil received in the heat exchanger 160 exchanges heat with the cold
15 fluid in the heat exchanger 160. The cold oil is then conveyed to the oil reservoir 110
through the second conduit via the flow meter 170.
In case of the auxiliary power source 135, the auxiliary power source 135 is coupled
to the first pump 120 and actuated to operate the first pump 120 before actuating the
component 130.
20 The test rig 100 does not involve use of an external electrical power source, thereby
eliminating need of electricity. More specifically, the second pump 220 and the
cooler 230 are operated using hydraulic power, i.e., oil pressurized by the first pump
120. This makes the test rig 100 portable in nature. Further, the footprint of the test
rig 100 is smaller than the footprint of conventional test rigs. For instance, if a
25 conventional test rig requires area of 10 square meter for testing a particular
component, the test rig 100 occupies area of 0.5 square meter.
14
Further, due to use of oil in the test rig 100, the fluid storage requirement is also
reduced. For instance, if a conventional test rig requires a water tank of capacity
10000 liters, the test rig 100 requires an oil reservoir of capacity 120 liters to perform
testing of a component.
Further, the test rig 100 provides accurate test results. As the pressure gauge 5 140 is
arranged immediately after the first pump 120, accurate pressure readings can be
obtained using the test rig 100. Further, in case a part of a component fails to operate
during testing, it can be immediately detected using the pressure readings provided by
the pressure gauge 140, and the testing can be stopped. This saves valuable time as
10 the failure of the part is detected immediately.
The foregoing description of the embodiments has been provided for purposes of
illustration and not intended to limit the scope of the present disclosure. Individual
components of a particular embodiment are generally not limited to that particular
embodiment, but, are interchangeable. Such variations are not to be regarded as a
15 departure from the present disclosure, and all such modifications are considered to be
within the scope of the present disclosure.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages
including, but not limited to, the realization of a regenerative test rig that:
20  eliminates need of an external power source;
 has reduced footprint as compared to conventional test rigs;
 facilitates performance evaluation of a component during testing;
 is durable; and
15
 is portable.
The embodiments herein and the various features and advantageous details thereof
are explained with reference to the non-limiting embodiments in the following
description. Descriptions of well-known components and processing techniques are
omitted so as to not unnecessarily obscure the embodiments herein. The example5 s
used herein are intended merely to facilitate an understanding of ways in which the
embodiments herein may be practiced and to further enable those of skill in the art to
practice the embodiments herein. Accordingly, the examples should not be construed
as limiting the scope of the embodiments herein.
10 The foregoing description of the specific embodiments so fully reveal the general
nature of the embodiments herein that others can, by applying current knowledge,
readily modify and/or adapt for various applications such specific embodiments
without departing from the generic concept, and, therefore, such adaptations and
modifications should and are intended to be comprehended within the meaning and
15 range of equivalents of the disclosed embodiments. It is to be understood that the
phraseology or terminology employed herein is for the purpose of description and not
of limitation. Therefore, while the embodiments herein have been described in terms
of preferred embodiments, those skilled in the art will recognize that the
embodiments herein can be practiced with modification within the spirit and scope of
20 the embodiments as described herein.
The use of the expression “at least” or “at least one” suggests the use of one or more
elements or ingredients or quantities, as the use may be in the embodiment of the
disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has
25 been included in this specification is solely for the purpose of providing a context for
the disclosure. It is not to be taken as an admission that any or all of these matters
form a part of the prior art base or were common general knowledge in the field
16
relevant to the disclosure as it existed anywhere before the priority date of this
application.
The numerical values mentioned for the various physical parameters, dimensions or
quantities are only approximations and it is envisaged that the values higher/lower
than the numerical values assigned to the parameters, dimensions or quantities fa5 ll
within the scope of the disclosure, unless there is a statement in the specification
specific to the contrary.
While considerable emphasis has been placed herein on the components and
component parts of the preferred embodiments, it will be appreciated that many
10 embodiments can be made and that many changes can be made in the preferred
embodiments without departing from the principles of the disclosure. These and other
changes in the preferred embodiment as well as other embodiments of the disclosure
will be apparent to those skilled in the art from the disclosure herein, whereby it is to
be distinctly understood that the foregoing descriptive matter is to be interpreted
15 merely as illustrative of the disclosure and not as a limitation.

WE CLAIM:
1. A regenerative test rig (100) for testing a power generation or transmission
component (130), said test rig (100) comprising:
an oil reservoir (110);
a first pump (120) in fluid communication with said oil rese5 rvoir
(110);
means (138) to couple said first pump (120) to said power generation
or transmission component (130);
a fluid reservoir (210);
10 a second pump (220) in fluid communication with said fluid reservoir
(210);
a first hydraulic motor (222) actuated by oil delivered by said first
pump (120), and configured to operate said second pump (220);
a heat exchanger (160) configured to receive oil delivered by said first
15 pump (120) and a cold fluid from said fluid reservoir (210) to facilitate
heat transfer therebetween;
a flow meter (170) for measuring flow of oil flowing through said test
rig (100) in an operative configuration of said test rig (100); and
optionally a pressure gauge (140) for measuring pressure generated
20 during the operation of said first pump (120) in an operative
configuration of said test rig (100).
2. The regenerative test rig (100) as claimed in claim 1, which includes said flow
meter (170) and said pressure gauge (140).
3. The regenerative test rig (100) as claimed in claim 1, which includes a cooler
25 (230) in fluid communication with said second pump (220), and configured to
reduce temperature of fluid received therein.
4. The regenerative test rig (100) as claimed in claim 3, wherein an inlet of said
cooler (230) is in fluid communication with an outlet of said second pump
18
(220), and an outlet of said cooler (230) is in fluid communication with an
inlet of said heat exchanger (160).
5. The regenerative test rig (100) as claimed in claim 3, wherein an inlet of said
cooler (230) is in fluid communication with an outlet of said heat exchanger
(160), and an outlet of said cooler (230) is in fluid communication with 5 an
inlet of said fluid reservoir (210).
6. The regenerative test rig (100) as claimed in claim 3, which said cooler (230)
is an air cooler.
7. The regenerative test rig (100) as claimed in claim 3, wherein said cooler
10 (230) includes a fan configured to reduce temperature of fluid received in said
cooler (230).
8. The regenerative test rig (100) as claimed in claim 3, which includes a second
hydraulic motor (232) actuated by oil received from said first pump (120), and
configured to operate said cooler (230).
15 9. The regenerative test rig (100) as claimed in claim 8, wherein an inlet of said
second hydraulic motor (232) is in fluid communication with said first pump
(120), and an outlet of said second hydraulic motor (232) is in fluid
communication with an inlet of said heat exchanger (160).
10. The regenerative test rig (100) as claimed in claim 8, wherein a flow control
20 valve (190) is configured to receive oil delivered by said first pump (120) and
deliver the oil to said first hydraulic pump (222) and said second hydraulic
pump (232).
11. The regenerative test rig (100) as claimed in claim 8, which includes a
pressure relief valve (150) configured to receive oil from said first pump (120)
25 and allow oil flow to said the first hydraulic motor (222) and second hydraulic
motor (232) when oil pressure generated by said first pump (120) exceeds a
preset pressure value.
12. The regenerative test rig (100) as claimed in claim 11, wherein said pressure
gauge (140) is connected between said first pump (120) and said pressure
30 relief valve (150).
19
13. The regenerative test rig (100) as claimed in claim 1, wherein said first pump
(120) is a vane pump.
14. The regenerative test rig (100) as claimed in claim 1, which includes a safety
valve (180) connected between said first pump (120) and said oil reservoir
(5 110).
15. The regenerative test rig (100) as claimed in claim 1, which includes a conduit
configured to convey oil from said heat exchanger (160) to said oil reservoir
(110).
16. The regenerative test rig (100) as claimed in claim 1, wherein said flow meter
10 (170) is connected between said heat exchanger (160) and said oil reservoir
(110).