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FZG High-Speed Back-to-Back Gear Test Rig

Electric drives run at more than 20,000 rpm. Their gear oils are evaluated at roughly one tenth of that speed. The FZG high-speed back-to-back gear test rig closes this gap — at 22,500 rpm at the pinion and in standard FZG geometry, so that the established FZG standard tests remain fully available.

Design and Operating Principle

The high-speed FZG test rig is based on the standard FZG test rig. This, too, is a test machine with a power circuit. The drive gearbox and the test gearbox are connected by a functional shaft assembly and a torsion shaft. A locking clutch is located on the drive shaft train to apply the load. The torque is measured at the torsion shaft. The test rig is driven by a speed-controlled induction motor. The associated oil unit for injection lubrication features a cooling and heating system that maintains the test transmission oil at the desired temperature. The temperature of the transmission oil can be preset and monitored.

 

With an axle distance of 91.5 mm and a gear ratio of 1.5, the test rig conforms to the FZG standard geometry; the FZG-specific test wheels can be used.

Close-up of the test transmission in the FZG high-speed gear stress test stand
FZG High-Speed Gear Tension Test Stand with Open Cowl
Top view of the clamping circuit of the FZG high-speed test stand

Test Methods and Development Partnership

The test rig is designed for the test methods specified in DGMK 833 / FVA 988 I “E-Fluids@HighSpeeds.” Additional test methods for the high-speed range are currently being developed at the Gear Research Centre (FZG) at the Technical University of Munich.

The test rig was developed as part of the nationally funded Opt4E consortium research project on the synthesis and optimization of electric powertrains, in which the FZG is participating. The collaboration extends beyond the development phase: the test rig and test procedures are being further developed jointly.

Highlights and Tests

  • High speed at the pinion (22,500 rpm)

  • Sump and injection lubrication

     

  • Separate oil circuits for the transmission and test gearboxes
  • Use of FZG-specific test gears is possible
  • DGMK 833 / FVA 988 I “E-Fluids@HighSpeeds”
  • Additional test procedures currently being developed at TUM (FZG)
  • Structure-borne noise and vibration monitoring
  • Measurement data available in .tdms format
  • Variable threshold monitoring

Technical Data and Equipment

  • Max. speed at the pinion: 22,500 rpm
  • Max. torque: 600 Nm
  • Max. power in the tensioning circuit:
    • Current: 754 kW (18,000 rpm & 400 Nm at the pinion)
    • Target: 1,413 kW (22,000 rpm & 600 Nm at the pinion)
  • Gear ratio: 1.5
  • Center distance: 91.5 mm
  • Shaft diameter of test transmission: standard Ø30 mm
  • Transmission oil temperature: water-cooled
    • Efficiency: 60°–140°C
    • Seizing test: Depends on the power in the load circuit
  • Oil temperature of test gearbox: 60 °–140 °C (controlled, cooled, and heated).
  • Holding temperature for injection lubrication: 60°–140 °C
  • Oil flow rate: 0.3–5 l/min
  • Overall space requirements (L x W x H):
    • Test Rig: approx. 2.5 m x 0.9 m x 1.7 m
    • Oil unit: approx. 1.4 m x 0.95 m x 2.2 m
  • Weight:
    • Test Rig: approx. 3 t
    • Oil unit: approx. 720 kg

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