Lubrication tilting test bench

The lubrication tilting test bench is a highly specialized and advanced testing platform specifically engineered to assess the performance and reliability of critical components in electric vehicles (EVs). This includes essential systems such as drive motor electric control units, drivelines, powertrains, and electric drive axles. Given the unique operational environments that electric vehicles encounter—such as varying terrain, inclines, and dynamic driving conditions—the tilting test bench plays a crucial role in simulating these scenarios.

By incorporating a tilting feature, the test bench allows engineers to replicate real-world conditions where components are subjected to different angles and orientations, thus enabling a thorough investigation of lubricant behavior under gravitational influences and varying loads.

The testing process on the tilting bench encompasses several vital areas of evaluation, including performance tests, reliability assessments, and lubrication verification. Performance tests focus on determining how effectively the components function under specific conditions, evaluating factors such as response times, efficiency, and output. Meanwhile, reliability tests are designed to assess the durability and longevity of these components over time.

This aspect of testing is critical, as it helps identify potential failure points and ensures that the systems can withstand the rigors of prolonged use in demanding environments. Lubrication verification is equally important, as it ensures that the lubricants used in these systems can provide adequate protection and maintain optimal performance, even when components are tilted or subjected to different operational stresses.

Furthermore, the versatility of the lubrication tilting test bench allows for expansion to include comprehensive drive system performance testing. This capability enables engineers to conduct a holistic evaluation of the entire drive system’s efficiency and effectiveness, taking into account the interactions between various components under realistic operational conditions.

By integrating these various testing dimensions, the tilting test bench becomes an invaluable tool in the development and refinement of electric vehicle technologies, ultimately contributing to improved safety, performance, and reliability in the rapidly evolving automotive landscape. Through rigorous testing on this platform, manufacturers can ensure that their electric vehicles are equipped with robust and reliable systems capable of meeting the demands of modern driving conditions.

The lubrication tilting test bench test items

1. Lubrication test

   Carry out the tilting test according to the test program and measure the lubrication performance of the UUTs under different working speeds, different refueling amounts, and different tilting angles (no load).

    

2. No-load oil temperature test

   Tilting test according to the test outline, measuring the temperature rise performance of the UUTs at different tilt angles, different refueling volumes, and the highest working speed (no load).

    

3. Towing torque test

   Conduct the tilting test according to the test outline, record the curve of input speed change with the time of the UUTs, intercept a section from the curve, calculate the speed, and time change difference, and bring it into the formula to calculate the towing torque.

The mechanical part technical description

The lubrication tilting test bench is customized according to customer requirements. The mechanical part consists of the foundation base, tilting mechanism 1 (in the direction of pitch angle), tilting mechanism 2 (in the direction of tilting angle), driving mechanism, torque sensor, tooling base, etc. It is suitable for applying to the tilting test of the UUTs in the unloaded state at different tilting angles under the performance and endurance test.

• Non-standard customized installation workpiece of the UUTs is installed and fixed on the lubrication table frame through the rotating mechanism turn interface, the lubrication table is rotated, and the drive measuring part is suspended through the bearing seat as a whole and fixed on the base of the table body;
• The maximum load capacity of the test bench is not less than 2800kg, and the UUTs are working in a no-load state during the tilting test;
• The lubrication bench has a tilting function, and the tilting angle is continuously adjustable from -20° to +20°;
• The lubrication bench has a left-right tilt function, and the tilt angle is continuously adjustable from -13° to +13°;
• The tilting table is installed with angle sensors, which can simultaneously measure the tilt in the X,Y dual-axis direction. The tilting actuator adopts an electric mechanism, and the angle adopts closed-loop control;
• The tilting angle of the tilting table can be remotely controlled by the upper computer, and the angle can still be continuously adjusted or kept stable according to different working conditions after the test starts.

Tilting test bench tilting part

The tilting mechanism of the lubrication tilting test bench adopts a servo motor with a precision reducer to form an electric actuator and is installed with X,Y dual-axis angle measurement tilt sensor.

• Pitch angle: Measuring range: ±45°, adjusting range: ±30°; adjusting precision: ±0.5°; adjusting mode: automatic and manual adjusting.
• Tilt angle: Measuring range: ±45°, adjusting range: ±13°; adjusting accuracy: ±0.5°; adjusting mode: automatic and manual adjusting.

Safety shield (optional)

The safety shield is made of steel plate and is divided into two parts, upper and lower. The lower part of the bracket is fastened to the top of the iron base plate by a combination of clamps, and the upper part of the shield can be flipped open around the hinge and locked at two points after closing. The shield covers all the moving parts between the test piece and the loading machine ensures that no spatters will fly out when various accidents occur in the drivetrain part, and plays an effective protective role.

Lubrication 6 degrees of freedom tilting test bench for electric driveline

The lubrication 6-Dof test bench is a fully functional test stand that meets the developmental test needs of electric powertrains including 3-in-1, all-in-one, dual-wheel drive, and hybrid, and performs on-road scenario simulations.

Test bench overview

1. The lubrication 6-Dof test bench is applied to various test types such as system matching and certification of various configurations of UUTs.
2. The tilting test bench covers the testing of UUTs matching, joint adjustment, control system calibration, function and performance testing, reliability, non-standard verification, etc., which meets the requirements of relevant national and enterprise standards.
3. The tilting test platform has the ability to test the lubrication system in the whole scene of multi-attitude loaded power system, i.e. simulating the front and rear longitudinal tilt and left and right lateral tilt of the vehicle under different driving conditions, and it can control the two kinds of tilting situations individually and synthetically, and dynamically and at fixed angles.
4. The platform includes loading machine and its control system, high and low temperature environment warehouse, battery simulator, power analyzer, cooling control system, towing device, UUT attitude adjustment mechanism and related platform supporting facilities, etc.
5. The platform is equipped with conventional steady-state control, cyclic dynamic control and driving simulation (throttle-brake).

Main functions of lubrication 6-Dof test bench

1. Performance and reliability test: The test system provides the road load, environmental conditions, cooling conditions, analog and communication signals required by the UUTs.
2. Full-scenario lubrication system test for multi-attitude loaded power system: The bench can restore the real lubrication situation of the UUT loading to the maximum extent.
3. Load machines can be individually controlled (speed-torque, or used as a single load machine). Independent steady-state testing of individual hub motors or UUTs, control of torque and speed for each load machines.
4. Bench control system: modular setup (historical configurations for different samples can be directly recalled) for synchronized control of all equipment in the bench, synchronized data acquisition and storage, etc;

Mechanical structure of lubrication 6-Dof test bench

• UUT support and adjustment device: To meet the conventional UUT support and adjustment, with mechanical locking function, to facilitate accurate control of the sample height adjustment.
• UUT attitude adjustment device: To meet the conventional UUT adjustment, to realize the longitudinal tilt ± 45°, lateral tilt ± 45° direction adjustment, with mechanical locks and other ancillary protective devices
• Load machine position movement adjustment device: Axial movement can be carried out on the cast iron platform.
• Various rotating machinery protection devices

Dynamometer parameters of lubrication 6-Dof test bench

• Rated power: ≥ 400 kW, capable of continuous operation
• Rated torque: ≥ 5,000 Nm
• Maximum speed: ≥ 4,500 rpm
• Moment of inertia: ≤4.4 kgm²

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