Electrical & Hydraulic System for the Side Gear Box (LH & RH) Test Rig — tested hot, pressurised and loaded to ~150°C oil, 18 kgf/cm², 78–80 kW.

Servo drive, not on/off

Mechanical energy comes from a robust asynchronous servo motor rated at approximately 78–80 kW, up to about 2500 RPM, commanded by a servo drive with closed-loop encoder feedback. It supports constant-speed running for endurance and heat soak, controlled speed ramps for performance mapping, and step/transient profiles for shock and load simulation — with over-current, over-temperature and safe-shutdown protection built in.

Inline torque measurement

Torque is measured directly on the shaft with an inline sensor covering approximately 0–300 Nm, mounted between the motor output shaft and the gearbox input shaft. It captures torque versus speed in each gear, transient torque during clutch engagement and gear shifts, and how torque requirements change as the oil heats up — building a clear “good gearbox” torque signature to flag any deviation early.

Validate mechanical performance

Check whether the gearbox can transmit the required torque without abnormal noise, vibration or overheating, and confirm correct functioning in all gears under both light and heavy load.

Verify shift and actuation behaviour

Evaluate smoothness and repeatability of clutch engagement/disengagement, confirm the gear shift mechanism reaches and positively holds each gear position, and check brake actuation under controlled hydraulic load while rotating.

Assess thermal and lubrication performance

Study oil temperature rise under sustained loading and endurance runs, and examine gearbox behaviour at elevated oil temperatures closer to real service conditions.

Analyse NVH, fatigue trends & acceptance criteria

Capture noise and vibration signatures across the full speed range to identify early misalignment, bearing damage or gear tooth pitting, then run standardised test cycles for every gearbox leaving the factory with full traceability.