Transmission Test Bench

JKT transmission 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 transmission and 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.

Model Selection of Drive and Load motor

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:

Drive Motor Parameters for Longitudinal Gearbox / Reducer Test Bench:

Load Motor Parameters for Transmission / Reducer Test Bench:

Note: Environmental chambers are optional for transmission or reducer test benches.

JKT can provide customized products according to customer requirements.

MAIN TECHNICAL PARAMETERS

• Torque measurement control accuracy：±0.05%FS

• Speed sensor pulse resolution：1024/600pprppr

• Torque control accuracy：±(0.5~1)%FS

• Speed control accuracy：±(0.01~0.05)%FS

• The max vibration value of dynamometer（RSM）：≤2mm/s（no load）

• The bearing support temperature rise：≤35℃

• The max vibration value of the bearing support（RSM）：≤2mm/s（no load）

• DAQ sampling rate：1kHz

• Current measurement channel:4/6

• Voltage measurement channel:4/6

• Measurement accuracy of power analyzer: ±0.05%

• Temperature sensor measuring range: -50℃~200℃

• Measurement accuracy of temperature sensor: A class

• Vibration sensor measuring range: 0~20mm/s

Typical Application Project for Reducer test

Test benches test reducers or transmission of the commercial vehicle and passenger vehicle.

Main test contents:

• Efficiency test

• Torque test

• Speed test

• Differential test

• Temperature rise test

• Over-load test

• Steady-state test

• Maximum speed test

• Durability with temperature climate test

• CLTC/WLTC cycle condition test

• User-defined cycle condition test

• Controller calibration test

• Road load simulation test

• Accelerated response test

• Torque response test

• l 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