Voith installs state-of-the-art test bench for drives and transmissions, ensuring reliable and low-noise operation in extreme conditions

To ensure a drive’s reliable performance, even in the harshest conditions such as the icy terrains of Siberia or when exposed to severe heat, the test bench allows for testing in an extreme temperature range from -50°C to +85°C. Resistance to mechanical stress or ice buildup can be put to the test as well. Testing can be performed with wind flow velocities of up to 50 m/s (180 km/h) that relate to driving speeds of 360 km/h. In addition, the test bench is ideally suited for load testing and endurance runs with continuous operation of up to 24 hours, seven days per week. Further, a high grade of automation allows the simulation of real driving cycles.

Grade 2 accuracy measurement of sound power levels

Train manufacturers and operators are required to adhere to increasingly stricter standards in terms of noise emission. Due to its well-thought-out acoustic design, Voith’s new test bench provides grade 2 accuracy measurements of sound power levels in accordance with DIN ISO 3744. This degree of precision is unprecedented in the rail industry. Hereby, drives made by Voith or third parties can be optimized regarding their acoustic behaviors.

Powerful components demand powerful testing equipment

In order to assess the limits of high-performance rail components, the testing equipment needs to be equally powerful. Voith’s test bench achieves a nominal capacity of 1.9 MW with an input torque of 15 kNm at 8,000 rpm and an output torque of 60 kNm at 4,000 rpm. In addition, the CE-certified test bench has an overload capacity of 3,400 kW, enabling demanding testing procedures and a great range for highly dynamic simulations. The drive is height adjustable and can be positioned at a 90-degree angle to accommodate bevel gears. This is the basis to execute testing over the complete rail drive product range.

Maximum testing efficiency with minimized energy costs

Due to its flexible design, set-up times are kept brief, thus causing minimal downtime in between runs. In this way, testing efficiency is maximized significantly. The test bench’s four-quadrant operation helps to effectively minimize energy costs. Energy efficiency is further improved by its cooling unit, which actively recovers heat for reuse.

Stadler Rail is one of Voith's first customers to test a gear unit on the new test bench. The test run served in particular for detailed noise measurements and functional tests under cold ambient conditions.

“Our unique test bench provides the best conditions for the optimum further development of our gear units and turbo transmissions. Function tests, driving simulations and endurance runs can be carried out for all dimensions, from Siberian cold to desert-like heat. In addition, the acoustic design of the test bench enables precise measurement of noise emissions independent of the power range,” states Stefan Hülsmann, Research Engineer at Voith.

In addition to the rail components, Voith will also use the new test bench to continuously guarantee the high quality standard of its DIWA automatic transmissions for buses and other commercial vehicle components.