GEARTest – The Modular Gearbox Test Stand From 500 kW to 4.500 kW
GEARTest is a complete solution for full load testing of large gearboxes from 500 kW to 4,500 kW. CNC Design has developed this to meet the growing needs for full load testing of large gearboxes.
Today large industrial gearboxes are in high demand for industries such as:
- Energy - Wind turbines is a strong growth sector
- Mining - Conveyors and Mining equipment
- Transportation and Shipping - Mining Trucks, Ship transmissions
Customers are looking for proven reliability for gearboxes used in critical applications such as wind turbines. As a result gearbox manufacturers and re-builders are now required to fully load test gearboxes to ensure compliance. At the same time demand for gearboxes in critical applications is growing and having in house gearbox testing facilities is more and more required to win customer orders. In particular the testing requirements for wind turbine gearboxes are critical due to the high failure rate and expense for replacing these units on site.
GEARTeast is a modular complete solution for testing of all sizes and types of gearboxes in sizes up to 4,500 Kw (we also have larger ones). It is made from standard parts from Siemens so service and spares are available worldwide. The system is proven in a number of sites and is base on our experience in building many types of transmission testing units for various industry sectors. GEARTest can grow with your needs. For example if you buy a 1MW unit now and need to upgrade this to 2MW in future you can without wasting your initial investment.
Many companies are now bidding for large gearbox supply contracts and need to be able to test these for compliance to customer specifications. We can quickly provide you with a budget proposal and fixed delivery time (typically six months) and installation time (approx 4 weeks) so that you can bid knowing your costs and timing if you are successful.
Wind is a special case with new test standards emerging. For example “Guidelines for the Certification of Wind Turbines” Edition 2007 specifies in chapter 7.4: “…the final inspection of the mass-produced gearboxes shall take place after a trial run under partial load lasting several hours. The detailed test plan (also regarding noise assessment) shall be agreed by the gearbox manufacturer and the wind turbine manufacturer.” Testing of wind turbine gearboxes requires dynamic loading with very fast starting and stopping times. GEARTest is fully regenerative and with 130% peak overloading we can achieve all tests required.
GEARTest is a back-to-back setup to test the gearbox up to 100% full load. The test gearbox unit will be connected directly to a motor on one side and via a speed matching gearbox to a second motor on the other shaft. Depending on the type of gearbox the motor on the high speed side of the test unit will act as the driving motor or as the generating motor (load). We can measure variables such as bearing temperatures, gearbox sound levels and vibration as well as monitoring and testing gearbox functions such as lubrication flow.
The system is suitable for gearbox builders and reconditioners.