FIELD OF INVENTION

The present invention generally relates to the field of gearbox testing, particularly to a load test-rig. More particularly, the present invention' relates to a power re-:circulating system for load test of gearbox with the suitable arrangement of magnetic particle clutch (MPC) and torqueing gearbox.

BACKGROUND OF INVENTION

The power re-circulating test rigs has an advantage of low power motor requirement to test the gearbox of higher power ratings. Earlier power re-circulating concepts uses a conventional helical gear train arrangement, orthogonal gearbox arrangement and four square test rig. The power re-circulating gearbox test rig consists of an epi-cyclic gear train arrangement in torqueing gearbox, motor, geared motor, magnetic particle clutch, master & slave gearbox. Suitable arrangement of this setup provides an energy optimized test rig which is capable to test gearboxes of the same specifications without having to alter torqueing setup for each testing. Here the master and slave gearboxes are going to be tested, where those gearboxes are loaded on their input drive end. During operation, motor transmits only speed in terms of RPM, where the torque generated by the magnetic particle clutch transmitted to torqueing gearbox. The torque is controlled by varying the excitation of DC supply.

CN204203430 - “A four-quadrant feedback type explosion-proof permanent magnet synchronous motor loading testing device” describes “The utility model discloses a four-quadrant feedback type explosion-proof permanent magnet synchronous motor loading testing device comprising a detected motor (}) and-a load motor (2).The load
motor (2) is connected to the detected motor (1) through a pair of shaft coupling devices (3). The four-quadrant feedback type explosion-proof permanent magnet synchronous motor loading testing device also comprises a detection frequency converter (4), a detection electric reactor (5), a detection filter (6) and a detection voltage transformer (7). The detected motor (1) is sequentially in electrical connection with the detection frequency converter (4), the detection electric reactor (5), the detection filter (6) and the detection voltage transformer (7). The four-quadrant feedback type explosion-proof permanent magnet synchronous motor loading testing device further comprises a load frequency converter (8), a load electric reactor (9), a filter (10) and a load voltage transformer (11). The load motor (2) is sequentially in electrical connection with the load frequency converter (8), the load electric reactor (9), the filter (10) and the load voltage transformer (11). The beneficial effects of the utility model are that the four-quadrant feedback type explosion-proof permanent magnet synchronous motor loading testing device is applicable to large power exp|osjon-proof permanent magnet synchronous motor loading tests”.

CN214310802 - ‘"motor load test tool”, describes “the utility model provides a motor load test tool which is characterized in that a motor to be tested is placed on a motor mounting seat, and an output shall of the motor to be tested is connected with a brake assembly through a connecting assembly arranged on a bearing seat, so that the output shaft of the motor to be tested is in transmission connection with the brake assembly. The brake assembly is used for applying a load to the output shaft of the to-be-tested motor. The motor load test tool is simple in structure, loads can be applied to the to-be-tested motor only by operating the brake assembly, load tests of the to-be-tested motor are completed, meanwhile, the load force applied by the brake assembly is limited, and the motor load test tool is suitable for load tests of small motors”.
The research article titled - “Development of a Power Re-Circulating Gear Test Rig” describes “In order to evaluate the performance of gears,- a power re-circulating test rig has been designed and developed. The test rig consists of one pair of test spur gears and one pair of helical loading gears. The variation in gear loading is achieved by axial loading of the helical gear using a pneumatic actuator. The no load-starting feature in the test rig reduces the size of the motor. The test rig is equipped with multi-mode condition monitoring unit and computer data acquisition system. Continuous multi-mode monitoring, online data analysis and post data analysis make the system more versatile in accurately predicting the failure”.

The research article titled — “Design of a mechanically closed-loop test rig for testing aviation industry’s gearboxes” describes “A test rig with low energy losses that is suitable fortesting 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 as 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 behavior of the system. The validity of the system’s dynamic modeling is also investigated and verified”.

None of the above-mentioned prior articles neither teach nor disclose about versatile utilization of power re-circulating system for load test of various gearboxes without any alterations jn loading and powering unjt for all conditions.
OBJECTS OF INVENTION

One or more of the problems of the conventional prior art may be overcome by various embodiments of the system of present invention.

It is the primary object of the present invention is a power re-circulating method which accompany various types of gearboxes with master and slave gearbox configuration of same specification for testing.

It is another object of the present invention is altering of torque in torqueing gearbox without reduction in RPM with the aid of a magnetic particle clutch.

It is another object of the present invention, wherein the said torqueing Gearbox consist of an epi-cyclic gear train arrangement which helps for achieving loading and power transferring as a single unit at the same time test gearboxes (Master and Slave) can be replaceable within the specification limit.

It is yet another object of the present invention, wherein the said motor provides only RPM feed and loading is done by the magnetic particle clutch along with torqueing gearbox by taking advantage of rigid coupling.

SUMMARY OF INVENTION

It is an aspiect of the invention is Power re-circulating and energy optimised system for load test of gearbox using torqueing gearbox, comprising of:

A Motor;

A Geared motor;

A Magnetic Particle Clutch;

A Reduction gearbox;

A Torqueing gearbox;
A Torque sensor;

A Master gearbox; and A Slave gearbox,

The motor provides input speed to the torqueing gearbox, where the input pinion shaft transmits RPM to the torqueing gearbox through gear drive, and the torque generated from the magnetic particle clutch is transferred to the torqueing gearbox with the aid of the reduction gearbox,

wherein, the torque sensor is a device used to measure the amount of force generated on the system during dynamic power transmission.

It is other aspect of the-invention is a power re-circulating method which accompany

&

various types of gearboxes with master and slave gearbox configuration of same specification for testing and altering of torque during testing.

Another aspect of the invention is altering of torque through torqueing gearbox on master and slave gearbox without reduction in RPM with the aid of magnetic particle clutch.

Another aspect of the invention is the torqueing gearbox consist of an epiTcyclic gear train arrangement which helps for achieving loading and power transfer as a single unit to the master gearbox and the slave gearbox are replaceable within the specification limit.

Yet another aspect of the invention is motor provide only RPM feed and loading is done by magnetic particle clutch along with torqueing gearbox.
Further aspect of the invention is torque increased in the master gearbox without reduction in RPM owing to the suitable arrangement of the main motor, the geared motor, magnetic particle clutch, torque multiplying gearbox, master gearbox and slave gearbox gives the closed loop for power recirculating.

Further aspect of the invention is testing of higher power gearboxes, higher power motor is required in conventional which leads to higher cost price for developing of test system whereas in power-recirculating method for testing of higher power gearboxes, low powered system is used to meet the same requirements and also low cost than the conventional system.

BRIEF DESCRIPTION OF DRAWING

Figure 1: illustrates a Power re-circulating system for load test of gearbox using torqueing gearbox

Figure 2: is a graph of cycle used for testing RPM vs torque and power Figure 3: is a graph of torque vs current consumption Figure 4: is a graph of motor vs gearbox power consumption
DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING FIGURES

The present invention as herein described about a power re-circulating system for load test of gearbox using torque ing gearbox.

The power re-circulating test rigs has an advantage of low power motor requirement to test the gearbox with higher ratings. Earlier power recirculating concepts uses a conventional helical gear train arrangement, orthogonal gearbox arrangement and four square test rig. In this system the power re-circulating gear test rig consists of an epi-cyclic gear train arrangement in torqueing gearbox, a motor (1), a geared motor (2), magnetic particle clutch (3), a master gearbox (7) and a slave gearbox (8). A suitable arrangement of this setup provides an energy optimized test rig and able to test various gearboxes. Here the master gearbox (7) and the slave gearbox (8) are going to be tested, where those gearboxes are loaded on their input drive end. During operation, motor transmits only speed in terms of RPM, where the torque generated and transmitted to a torqueing gearbox (5) through the magnetic particle clutch (3). This is controlled by varying the excitation of the magnetic particle clutch (3) by DC supply.

Each component of the embodiment works together to achieve the said system. The loading unit consists of the geared motor (2), the magnetic particle clutch (3) and a reduction gearbox (4). The geared motor (2) is majorly used in industrial application. It has a major advantage of achieving higher ratio in a constrained space. Here jt helps for achieving; higher torque oh the magnetic particle clutch (3) at slow speed. The' magnetic particle ciutch (3) by taking advantage of rigid coupling (9) is a special type of electromagnetic clutch which does not use friction plates. Alternatively, an iron particles (typically magnetic property) are used to mechanically link a free-wheeling disc attached to one shaft, to a rotor attached to the other shaft. The magnetic particle clutch (3) is used for controlled transmission of torque to the application device, which has magnetic powder in between input and output shaft when excitation current passes
through it creates a bond between input and output shaft. And bond linkage is directly proportional to the amount of current passes through and which a|so correspondence to torque transmittable. The reduction gearbox (4) helps in multiplying torque generated after from the magnetic particle clutch (3) for providing greater torque to hold one of the gear in epi-cyclic gear train on the torqueing gearbox (5). The gearbox is powered by the driving motor capable of speeds up to 1500 rpm, and the input power can arrive at about 75 kW, The MPC (3) and torqueing gearbox act as a loading unit to simulate various ioading conditions on the master and slave gearbox. The driving speed and loading torque can be regulated within a certain range. It consists of Epi-cyclic gear train. An Epi-cyclic gear train (also known as a planetary gearbox) consists of three gears mounted so that the center of one gear revolves around the center of the others. Planet Carrier rotates on its axis such that the planet gears revolve around the sun gear and makes the ring gear to turn on its axis.

An electric motor (1) is an electrical machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between the motor's magnetic field and electric current in a wire winding to generate force in the form of torque applied on the motor's shaft. It helps to rotate the gearbox and shafts to increase the RPM. Both the master gearbox (7) and the slave gearbox (8) are the testing gearboxes, where the inputs are connected to the output of Torqueing gearbox, through which loading happens. In this case, an orthogonal gearbox is used. The master gearbox- (7) and die slave gearbox- (8) used are opposite handjng that js when viewed from input the master gearbox (7) is LH handing then the slave should be in RH handing. Output of both the gearboxes are connected with solid shaft so that the loop remains in closed condition. A torque sensor (6) is a device used to measure the amount of force generated on the system during dynamic power transmission. Herein, used rotary type torque sensor which uses a pair of piezo electric crystal mounted over the shaft in V shaped on both the sides of shaft. During power transmission, torque creates a mirror elastic twisting on the shaft which caused the piezo crystal to generate
electricity on its opposite faces and the help of slip ring voltage is transmitted to signal conditioner where the respective voltage |s plotted against the respective torque range that is 0-1OV against 0-5000Nm torque.

Embodiment functions as the torqueing gearbox (5), has an epi-cyclic power train and simple drive train arrangement. It plays an important role in' power recirculating load test rig by re-circulating the power from the motor (1) and loading unit to the master gearbox (7) and the slave gearbox (8). The torqueing gearbox (5) is built in such a way that jnput RPM is same as output RPM,-torque varying js performed by the Magnetic Particle Clutch (3) by taking advantage of rigid coupling (9). The torqueing gearbox (5) consist of an input pinion shaft (that is through drive shaft), an epi-cyclic gear train arrangement and an output shaft. Initially, the motor (1) provides input RPM to the torqueing gearbox (5) where the input pinion shaft transmits RPM to the torqueing gearbox through gear drive, and the torque generated is transferred to the torqueing gearbox with the help of the Magnetic Particle Clutch (3) and the reduction gearbox (4). The Magnetic Particle Clutch (3) is excited separately with a controllable DC source for transmitting required torque from the geared motor (2) to the reduction gearbox (4) which helps in stepping up the torque to hold one of the gear in epi-cyclic gear train. Using the suitable combination of the epi-cyclic gear train, output is' derived through the spur gear arrangement which is then transferred to the master gearbox (7) or the slave gearbox (8). Output of the master gearbox (7) and the slave gearbox (8) are connected with solid shaft for re-circulating power to the torqueing gearbox (5) itself. Since, both the master gearbox (7) and the slave gearbox (8) are connected to the torqueing gearbox (5) by rigid coupling (9) connection, any model and variants irrespective of size and length can fit into this system. Functional running cycle is something that is used to find the system response for the input torque and RPM of the given cycle time period and also helps for a new system before directly enter into test cycle uses this cycle to find and analyze the response of the system.
Referring to 2, using the cycle mentioned above lest was conducted for about 120 mins (2 hours); on which each step has undergone for at least 3 minutes of soak time for accurate values by allowing the gearbox as well motor to be stabilized and the values are taken the PLC SCADA software integrated with VFD. Torque value was measured using Piezo electric based torque sensor and RPM was measured using Inductive based proximity sensor

Gearbox power was calculated using the formula

Power (kW) = Speed (RPM) x Torque (Nm)/9548.8 And motor power was calculated using the formula

Power (icVA) = Voltage (Volt) x Current (Amps)

By maintaining same voltage (415 — 430 VAC) and the current for each step was measured on VFD and the data were extracted through PLC.

For loading the gearbox from lower to higher torque, mechanical power in the system is increases which eventually increases electrical power, but in power re-circulating method instead of same power consumption, this system consumes less power.

Referring to figure 4,- it’s clearly indicated that motor power consumption is lesser than the power consumed by the master gearbox (7) or the slave gearbox (8). Thus, by taking the advantage of power recirculating test-rig using epi-cyclic gear-train one can achieve loading of higher power gearboxes by using lower power of the motor (1) itself. Range of loading can be achieved by design considerations and the ratio split up of the torqueing gearbox (5).

Embodiment in addition supports,-torque is increased in the gearbox without reduction iii RPM. Suitable arrangement of the main motor, geared motor, MPC, torque multiplying gearbox, master and slave gearbox gives the closed loop for power recirculating. For testing of higher power gearboxes, higher power motor is required in conventional which leads to higher cost price for developing of test system whereas
in Power-recirculating method for testing of higher power gearboxes, low powered system itself can be used to meet the same requirements and is also cost-effective than the conventional system.