Test bench up to 15000 Nm
The company Schmahl produces gears for construction equipment that has to be produced exactly due to special demands. In order to avoid production- and material defects a test bench was developed in cooperation between the companies Schmahl, Bosch Rexroth and Quality Automation on which you let up to 15000 Nm sink in. The test bench is constructed in that way, that the drive and the outputs of electrical motors are simulated.
Drive and adjustment control with the MLD of Bosch Rexroth
The MLD of Bosch Rexroth drives and controls the motors, in doing so it serves also as SPS and controls e.g. the hydraulic system and gathers measuring values via analogue inputs. The power element of the IndraDrive series consists of a supply unit, two intermediate circle resistors and control equipment for each motor. The capacity of the supply unit comes to 120 KW, the motors have a nominal load of in total 141 KW. The MLD as central drive and control equipment is connected with the control units, the I/Os und the analogue units via Sercos Bus.
TCP connects the systems
The test bench is visualized by a LabView application that communicates with the MLD via TCP/IP. The motors and all control components can be controlled separately during the service operation. A test cycle is prepared with this application and saved in a data bank. This is provided in that way that the control programs are put in by the quality assurance and that the single gears can be tested by the operator via an order administration. The data of the test cycle contain driving speed, full load as well as temperature, distance measurement and an impact sound measurement. These data can be saved in the data bank in a cycle of 10ms.
All from one source
The project was realised exclusively by Quality Automation except the mechanical works. It includes the electrical construction, the construction of switchboard cabinets, the software for the MLD and the LabView application.