Ultra-high rotational speed testing over 150,000 rpm

The demand for ultra-high rotational speed testing is rapidly growing, particularly for applications such as electric spindles, fuel cell air compressors, and centrifugal compressors designed for hydrogen fuel cells. As industries increasingly focus on efficiency and performance, the need for rigorous testing of devices operating at speeds exceeding 150,000 rpm has become paramount.

This requirement extends to a variety of other applications, including electric superchargers, small turbo compressors, aeronautical turbochargers, turbochargers for electric drives, and even high-performance vacuum cleaners. These devices must not only meet demanding technical specifications but also demonstrate reliability and efficiency under complex operational conditions.

To support the development and testing of these advanced devices, specialized ultra-high rotational speed testing equipment is essential. This equipment is engineered to handle the unique challenges associated with high-speed applications, ensuring that each device can be thoroughly evaluated for performance, safety, and durability.

For instance, ultra-high rotational speed testing equipment designed by industry leaders includes advanced features that cater specifically to spindle, turbo, and air compressor tests. This specialized testing apparatus integrates a load machine with a speed increaser, allowing engineers to simulate a wide range of operational scenarios.

The load machine itself operates in a four-quadrant mode using a frequency converter, providing the capability to both drive and brake the unit under test (UUT). This dual functionality is crucial for accurately assessing the performance characteristics of devices at ultra-high speeds. The testing equipment also offers flexibility by enabling operation in either drive speed or torque control mode, which allows engineers to tailor the testing conditions to meet specific requirements.

By facilitating detailed performance assessments, this specialized testing equipment plays a vital role in rapid product development and qualification, ensuring that new technologies can be brought to market efficiently and reliably. Overall, ultra-high rotational speed testing is essential for advancing the capabilities of modern engineering applications, driving innovation, and enhancing the performance of high-speed devices.

The ultra-high rotational speed testing equipment is specifically designed to apply variable mechanical loads to the Unit Under Test (UUT) while operating at exceptionally high speeds. This capability is crucial for conducting comprehensive tests that replicate the challenging conditions encountered in real-world applications. These conditions include factors such as elasticity, vibration, and dynamics, all of which can significantly impact the performance and longevity of devices operating at ultra-high speeds.

Additionally, the equipment addresses automation requirements that enhance safety during testing, ensuring that all procedures adhere to industry standards and best practices.

One of the standout features of this testing equipment is its ability to ensure precise control and measurement of test parameters. This precision is vital for accurately evaluating and analyzing the performance of the device under test.

By maintaining stringent control over variables such as speed, load, and torque, engineers can obtain reliable data that reflects the true performance characteristics of the UUT. This data is essential for identifying potential weaknesses or areas for improvement, allowing manufacturers to refine their designs and enhance product reliability.

By utilizing DynoEquip’s ultra-high rotational speed testing equipment, manufacturers can effectively develop and validate their products to meet the stringent demands of the market. The equipment’s versatility allows it to accommodate a wide range of applications, from electric spindles to turbochargers, making it an invaluable tool for engineers working in various sectors.

Furthermore, its reliability contributes to shorter product development cycles and qualification periods, enabling manufacturers to bring their innovations to market more quickly. In a rapidly evolving field where speed and efficiency are paramount, this testing equipment empowers manufacturers to stay ahead of the competition, ensuring that their products not only meet but exceed industry standards for performance and safety.

Over 150,000 rpm ultra-high rotational speed testing applications

1. Gas turbines

   Gas turbines used in aerospace and power generation applications operate at ultra-high rotational speeds. load machines are essential for testing the performance, efficiency, and durability of these turbines under different load conditions. They help measure parameters such as power output, torque, and fuel consumption, providing valuable data for optimizing turbine design and operation.

    

2. Automotive engine testing

   High-performance racing engines and advanced automotive powertrains often operate at ultra-high rotational speeds. Load machines simulate real-world conditions and evaluate engine performance, emissions, and durability. They enable precise control overload conditions, allowing engineers to measure power output, torque, and other performance metrics.

    

3. Research and development

   Various research and development projects in fields like aerospace, robotics, and advanced manufacturing involve ultra-high rotational speed applications. load machines play a critical role in testing prototypes and experimental systems. They help researchers evaluate performance, validate designs, and fine-tune parameters for optimal operation.

    

4. Spindle testing

   Ultra-high rotational speed spindles used in machining centers, milling machines, and other precision equipment need thorough testing. Load machines allow for the evaluation of spindle performance, stability, and vibration levels. They help identify any issues related to balance, heat generation, and bearing performance, ensuring the spindle operates smoothly and accurately.

    

5. Turbocharger testing

   Turbochargers, commonly used in automotive and marine engines, operate at high speeds to increase engine power. Load machines are employed to assess turbocharger efficiency, boost pressure, and compressor performance. These tests aid in optimizing turbocharger design, improving engine performance, and reducing emissions.

The turnkey ultra-high rotational speed testing solution exceeding 150,000rpm

1. Speed increaser

   The Germany ultra-high rotational speed testing speed increaser can handle the torque and power requirements of the UUT.

    

2. Mounting and integration

   Properly mount and integrate the speed increaser with the load machine. Ensure that the output shaft of the speed increaser aligns with the input shaft of the load machine and establish a secure connection.

    

3. Power source

   Connect the speed increaser to a suitable power source capable of driving it at the desired speed range.

    

4. Lubrication

   Follow recommended lubrication practices to minimize friction, heat generation, and wear. Use the appropriate lubrication type, quantity, and frequency.

    

5. Calibration

   Calibrate the load machine and speed increaser system to ensure accurate and reliable measurements. Follow the recommended calibration procedures.

    

6. Safety precautions

   Necessary safety measures are implemented, such as safety enclosures and personal protective equipment, to ensure the safety of personnel and ultra-high rotational speed testing equipment during testing.

    

7. Test setup and parameters

   Define the ultra-high rotational speed testing parameters, including the desired speed, load conditions, and test duration. Establish specific performance criteria and measurements to be recorded during testing.

    

8. Data collection and analysis

   Collect and analyze the data obtained during testing using appropriate data acquisition systems. Evaluate factors such as torque, power, and efficiency based on the defined performance criteria.

    

9. Maintenance and support

   Perform routine maintenance on the speed increaser and load machine system. Clean and lubricate the components as recommended. Seek support or assistance as needed.

The main structure of ultra-high rotational speed testing equipment

Ultra-high rotational speed testing equipment base

The base of the ultra-high rotational speed testing equipment is engineered with integral casting structural parts, which provides superior strength and stability essential for handling the intense forces generated during high-speed operations. This robust design ensures that the entire assembly can withstand the significant mechanical stresses encountered during testing.

The upper surface of the base is meticulously crafted as an assembled surface, allowing for precise alignment and secure attachment of the various components that make up the testing system. After undergoing precision machining, which guarantees a high degree of accuracy and smooth finishes, the base is further enhanced by the installation of four air spring shock absorbers positioned at the bottom.

These shock absorbers play a critical role in vibration isolation and damping, effectively mitigating any vibrations generated during operation. By absorbing and dissipating these vibrations, the air spring shock absorbers contribute to maintaining the integrity of the testing environment, ensuring that the measurements obtained during tests are accurate and reliable.

This thoughtful combination of materials and engineering not only enhances the performance of the testing equipment but also extends its lifespan, making it a valuable asset in the realm of ultra-high rotational speed testing.

Ultra-high rotational speed increaser

The speed increaser utilizes a two-stage power distribution transmission with coaxial input and output shafts with the following parameters:

• Rated output speed: 165,000 rpm
• Rated output torque: 1.5 Nm
• Rated power: 25 kW
• Service life of all gearbox components > 10,000 hours
• Designed for torque and speed in all directions (4Q operation)
• 250mm x 300mm x 350mm
• Center height 200 mm
• Central connection for lubrication, piping, and oil inlets
• Safety switch for oil pressure detection
• Mounting thread for vibration sensor
• Includes 3 temperature sensors

As a key component of the speed increaser, the lubrication pump station is extremely important, which is supplied by the speed increaser supplier at the same time and is commissioned before leaving the factory.

• For oil volumes of up to approx. 30 liters.
• Water-cooling connection
• Temperature sensor included
• Including oil level sensor
• 600 mm x 700 mm x 400 mm

Torque measurement of UUT

The torque measurement of the UUT is done directly, not by installing the torque speed sensor at the low-speed end, avoiding the transmission loss of the speed increaser to be included in the measurement data of the UUT.

• Accuracy
  • Linearity deviation and hysteresis (total system): 0.1 %
  • Repeatability < 0.03 %

• Amplifiers and non-contact signaling
  • Integrated rotary adjustable amplifier
  • Integrated temperature drift compensation
  • Non-contact transmission based on sensor-telemetry technology
  • Integrated rotor sensing loop

• Rotor antenna
• Pickup antenna
• Factory calibration certificate ISO 10012
• Temperature range -10… +85 °C
• Integrated design in the speed increaser housing
• Additional housing length approx. 100 mm

Speed measurement of UUT

• Dynamic rotational speed measurement for high-speed shafts over 150,000 rpm
• Temperature range -10… +85 °C

Highly dynamic control system

• The ultra-high rotational speed testing equipment adopts a very advanced system architecture, using the embedded real-time controller as the control center, the real-time controller is equipped with the main control program, very stable and reliable.
• The real-time controller communicates with the frequency converter through the fastest and most stable real-time Ethernet, EtherCAT, to dynamically control the load machine.
• The data acquisition system also adopts a modularized structure and communicates with the real-time controller through EtherCAT for data interaction, which is very convenient for subsequent channel expansion.
• The upper computer adopts a special industrial computer, which is equipped with human-machine interface software for the display and saving of data, as well as the issuance of manual commands and so on.
• As the upper computer generally uses Windows system, the system as an operating system for industrial control is not very suitable, therefore, we use an independent embedded real-time controller control.
• Real-time controller external touch screen can be operated through the touch screen on the testing equipment, to prevent the upper computer is dead and other phenomena, cannot be controlled.
• The dynamic response time of the ultra-high rotational speed testing system is better than 10ms, which can provide highly dynamic control to meet the complex variable operating conditions and simulation testing.

Comprehensive security measures

• Real-time monitoring of bearing and temperature at the front and rear of the load machine, real-time monitoring of current and voltage, speed, and torque.
• Real-time monitoring of the bearing temperature and vibration of the speed increaser.
• Real-time monitoring of the vibration of the UUT.
• Safety shield closure detection and load machine to form a chain of protection.
• The electric control system has protection functions against short circuits, leakage, power failure, over-current, and over-voltage.
• The ultra-high rotational speed testing system software has a safety detection function, when the monitoring value exceeds the threshold value, the alarm will be raised immediately. The system has a three-level protection function.
• For durability testing, the ultra-high rotational speed testing system automatically makes trend predictions based on the monitored vibration and other historical data, and the system prompts the user to pay attention when a failure is predicted to occur.

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