Automatic functional test rig for gear pumps
Maximum load testing of gear pumps.
This project involved the design, construction, and assembly of an automated functional test rig for gear pumps by WEBER.
The pre-assembled gear pump is placed onto a workpiece carrier (WPC) by a handling system. A conveyor system with data storage and a read/write system transports the WPC to the removal position. An automated loading and unloading handling unit then removes the pump to be tested and places it into one of two test nests. There, flow rate, pressure pulsation, pressure, and torque are measured. The measurement results are stored, enabling statistical analysis.
Technical description
- Cycle time – 20 seconds
- Test temperature – 100 °C across 4 different oil circuits
- Load testing – up to 40 bar oil pressure
- Leak testing – of oil channels within its own circuit
- Hydraulic tension testing – as part of the test sequence
- Gear pump drive – up to 8,000 rpm via a water-cooled servo motor
- Measurement data acquisition – via a real-time system from National Instruments
- Test program development – in LabWindows
- Storage of measurement data – in an SQL database
- Data recording – for torque, pressure, temperature, and flow rate testing
- Pressure pulsation testing (FFT) – converting the amplitude spectrum (p[bar]) into the level spectrum (p[dB])
- Level addition analysis – of 24 pump frequencies
- Laser marking – by Trumpf, with DMC code verification via camera system
- Continuous filtration and monitoring of test oil – using a particle monitor
- Cleaning station – for the gear pump