Windpower Industry

Gearbox test rigs

01Modular test rig concept
02Simulation of real installation situation
03Intelligent oil supply systems

Our technologies for your demands

Gearboxes in wind turbines are subjected to extreme loads and are expected to operate reliably over a very long period of time. Realistic tests are therefore necessary.

Back-to-back setups are a proven standard for gearbox testing for decades. A whole range of components is possible for such a setup, which can be selected and combined with each other depending on the test item, special test requirements and required test rig modularity:

Drive and load systems (motors, drives, transformers, adaption gearboxes)
XYZ adjustment devices for motors
HSS couplings
Adjustable specimen supports
LSS couplings (main shaft)
Main shaft adjustments
Lubrication units
Cooling units
Load application units
Test rig foundation
Sound isolation
Safety equipment
Measuring equipment
Test rig control and automation system

This flexibility allows us to support our customers completely individually. From the upgrade of an existing system by a new component up to the complete realization of a new test facility.

Gearbox test rigs from RENK can be used for development purposes as well as for quality assurance at the end of production and after gearbox overhauls.

01 Modular test rig concept

Modular test rig concept for testing different gearbox designs

Test rigs for wind turbine gearboxes are usually required to test a range of different gearboxes. Not only do different sizes of a gearbox type have to be taken into account, but also different gearbox designs, such as three point or four point suspension for different turbine drive train configurations. Right from the start, RENK test rigs are designed in a modular way so that the various requirements can be met with minor modifications.

02 Simulation

Simulation of real installation situation

In most cases, wind turbine gearboxes are not only loaded with torque during operation. These additional loads from the rotor dynamics, main shaft bearing or gearbox weight are simulated in the test rig in order to represent an installation situation that is as realistic as possible. This is also done with the highest possible modularity.

03 Intelligent oil supply systems

Oil supply systems:
An important quality assurance tool.

For us, oil supply is not just a lubrication unit.

Before starting the test, the oil supply system is used to flush the gearbox to the required purity level.

During operation, the quality of the oil can be an important indicator of the operating behavior of the gearbox. Targeted measurements make it possible to monitor the gearbox oil online via the oil supply system. Conclusions regarding ideal operating states and the efficiency of the gearbox can be made based on these measurements.

04 measurement

Detailed measurement of gearbox efficiency

Due to our own use of large gearbox test rigs, we know very well that disturbing influences of the test rig such as vibrations or friction losses can strongly influence the measurement on the gearbox to be tested. Due to the consistent use of plain bearings in the drive train of the test rig, sophisticated designs and state-of-the-art manufacturing processes, we can offer our customers optimum test conditions with RENK test rigs.

In addition, we have great expertise in the selection and installation of the appropriate sensor technology as well as signal processing and measurement reporting with our RDDS test bench control system.