Gear Shift Test Rigs

Test Rig for Endurance Study of Gear Shift Mechanism

Gear Shift Test Rigs

Dynaspede's Gear Shift Test Rigs validate the design limits of endurance of gear shifter linkages under cyclic operating conditions. The Test bench has adequate versatility to put to test a variety of designs and validate the design limits of endurance of the shifter linkages under adverse operating conditions.

The test bench automates all cyclic sequencing with dynamic simulation of load profiles arising due to acceleration and deceleration of inertial loads of vehicles. The sequential testing in single or double clutching modes of gear shifting are possible by appropriate set-up menu on a dedicated PLC system and associated man-machine interface. The test bench accepts the test unit consisting of transmission case, centre housing and trans-axles with the two wheels mounted on them. The gear shifting sequence and dwell time in each gear position, as mapped in the software, are repeated for a specified number of cycles or till onset of failure.

Test Set-up

Mounting Arrangement: The Test unit, consisting of Transmission case, centre housing and transaxle housing is supported on the two adjustable pillars and flanged to the test bed by means of interchangeable adapter plates. Adapter plates, suiting the dimensions of various models of transmission units can be used for mounting different types of transmissions.

Gear/ Clutch lever actuation: Actuation of clutch mechanism and gear shifting lever are done through fast-acting pneumatic cylinders and associated electro-pneumatic devices controlled by a dedicated Programmable Logic Controller.

Force monitoring arrangement: Dynaspede’s exclusively designed force sensors are employed to separately monitor the gear shifting forces needed to shift the gear lever between gate positions and gear engagement.

Drive Arrangement: The input of the transmission is driven at adjustable speeds by an induction motor speed controlled by an AC motor controller. The adjustable speed drive is programmed with dynamic braking for fast deceleration.

Speed Measurement: Dynaspede 48-pole AC Tachogenerator monitors the driving speed of the transmission. A specially designed pulse-resolver separately monitors the wheel speed.

Control System: PLC based control system serves all the control needs of the Test Bench. The system automates all cyclic sequencing with dynamic simulation of load profiles arising due to acceleration and deceleration of inertial loads of vehicles. The sequential testing is in single or double clutching modes of gear shifting.