Benefit from the experience gathered from more than 200 installed test rigs for the aviation, automotive and petroleum industries as well as for manufacturers of antifriction and slide bearings

Special test rigsFor

material / gears / gearboxesantifriction bearings / slide bearingsDriveshafts and propshafts / clutch

Gearbox test rig for acoustic testing

8-station rotary table machine ProMoCut®

Metal cutting technology Cleaning technology

ProMoClean® cleaning machine and RoboClean robot cell

1 2 3Assembly and test engineering

ProMoCell® – the Strama-MPS standard assembly cell

Assembly and test engineering

Assembly and test engineering

Linear motorquick-change system ProMoChange®

Laser markingsystem ProMoScript®

One plus x modular standard solutions for greater productivity and flexibility

Strama-NCT LLCSubsidiary

2204 Kickapoo Drive Danville, IL 61832 USA

528B Brookshire RoadGreer, SC 29651USA

Engineering and manufac- turing of special purpose machines as well as sales and service location of the Strama-MPS group for the US market.

www.strama-nct.com

F & K Delvotec Bondtechnik GmbH Subsidiary

Daimlerstr. 5-7 D-85521 Ottobrunn Germany

Technological leader in inno-vative wire bonding.

www.fkdelvotec.com

Nexus d.o.o.Subsidiary

Kralja Zvonimira 19HR-32272 CernaCroatia

Manufacturing of high quality welded and milled components as well as steel construction.

www.nexus-com.hr

AuE Kassel GmbHSubsidiary

Heinrich-Hertz-Str. 52D-34123 KasselGermany

Global market leader in adjustment systems for axles.

www.aue-kassel.de

Strama-MPSHead office & Plant Danube

Head officeIttlinger Str. 195Plant DanubeBanater Str. 10D-94315 StraubingGermany

Technological leader in metal cutting technology, cleaning technology, photovoltaic, assembly and testing techno-logy, spe-cial test rigs, body welding and assembly systems for au-tomotive, electrical and solar industry.

www.strama-mps.de

Strama-MPS Machinery Taicang Ltd. Subsidiary

Shiny Science Park Building 6, No. 111 North Dongting Road, 215400 Taicang JiangsuP.R. China

Engineering and manufac-turing of special purpose machines as well as sales and service location of the Stra-ma-MPS group for the Asian market.

www.strama-mps.cn

Strama-MPS MaquinariaSubsidiary

Oficinas Premium Centro de Negocios, Oficina 21Av. Juárez 2915-101Col. La Paz, Puebla Mexico

Engineering and manufac-turing of special purpose machines as well as sales and service location of the Strama-MPS group for the central and south american market.

www.strama-mps.de

Strama-Summit Machinery Pvt. Ltd. Subsidiary

F-93, M.I.D.C, AmbadNashik-422010 India

Engineering and manufac-turing of special purpose machines as well as sales and service location of the Strama-MPS group for the Indian market.

www.stramasummit.com

STRAMA-MPS – Our history and locations

2015

Foundation1946

Business extensionto fixture construction

1969

Foundation oftesting division

1993

Expansion with • F&K Delvotec Bondtechnik GmbH• Strama-NCT LLC

2014

Foundation factory Donau

2013

Expansion with • Strama-MPS U.S. Inc.• Nexus d.o.o. (Croatia) • AuE Kassel GmbH• Strama-MPS Machinery Taicang Ltd.

2003-2013

Expansion with • Strama-MPS Maquinaria (Mexico)• Strama-Summit (India)

LOGO STRAMA Summit India international 4c

Table of contents

Page 4■ FZG gear test rig

■ Gear test rig for fatigue and strength testing

Page 5■ Test rig for the determination of material characteristics■ Gear test rig with variable center distance■ System Flender oil foam test ISO 12152

Page 6■ Hypoid gear test rig■ Worm gear test rig■ Back-to-back planetary gearbox test rig

Page 7■ Antifriction bearing test rig■ Antifriction and slide bearing test rig■ Bearing test rig for turbochargers

Page 8 ■ Propshaft test rig■ Propshaft test rig for four shafts■ Driveshaft test rig

Page 9 ■ Gearbox test rig for acoustic testing■ Endurance test rig for gearboxes ■ Filterability test rig

Page 10 ■ Clutch test rig■ Blower test rig■ Turbine wheel test rig

Page 11 ■ Bevel gear test rig TS-30

Tests■ Limiting stress capacity of lubricants according to DIN 51354 ■ Micropitting test ■ Standards ISO 14635, CEC-L-07, CEC-L-084, ASTM D 5182, ASTM D 4998, FVA 243, FVA 54, FVA 2/IV, FVA 345, FVA 371■ Determined characteristics: Scuffing load capacity, pitting duration, micropitting formation■ Target sectors: Automotive and petroleum industry Technical data and equipment ■ Speed range: 0 – 3,000 rpm■ Max. torque: 715 Nm■ Center distance: 91.5 mm

Energy recovery in the power circuitWhen testing gearboxes, shafts or clutches, test rigs based on a closed power circuit use up to 95 % less energy compared to a brake test rig. The input energy circulates between the test gearbox and the drive gearbox, which are connected by two torsion shafts. To generate the torque, a load clutch is attached to one of the shafts. After start-up, all the energy required for the test – except for gearing and bearing energy losses – remains in the test circuit and the load motor must only provide about 5 % lost energy.

In recent years, Strama-MPS delivered about 200 test rigs based on a mechanical power circuit. Special test rigs, for ex-ample for testing hypoid gears, propshafts, load cycles or efficiency, are developed and manufactured in addition to the standardized FZG gear test rig.

FZG gear test rig

The FZG gear test rig for endurance testing of lubricants and gear materials in accordan-ce with DIN 51345 is manufactured exclusively at Strama-MPS, under a license of the technical university of Munich (TU Munich). The standardized test sequence enables the comparability to other products and materials, ensures reproducibility of the tests and in this way makes a valuable contribution to quality assurance in the lubricant industry.

Tests■ Gear fatigue and strength testing■ Especially suited for high speeds and torques ■ Target sectors: Automotive and petroleum industry

Technical data and equipment ■ Variable speed: 0 – 5,000 rpm■ Torque: 0 – 6,000 Nm■ Temperature (cooling and heating): - 20° C to + 120° C■ Center distance: 160 - 200 mm■ Vibration monitoring■ Evaluation using LabVIEW

Four-square gear test rig for fatigue and strength testing

This endurance test rig is suited to test the fatigue and strength of gears. It is based on a closed circuit principle and is especially designed for high torques. The hydraulic load clutch with an integrated hydraulic system is connected to the control unit of the test rig, enabling automatic adjustment of the load torque.

Tests■ Determined characteristics: Service life, tooth root bend, efficiency, speed, torque, temperature, vibration■ Especially suited for high torques ■ Flexible use: for gears, worm gears, bevel and ring gears■ Target sectors: Automotive and petroleum industry

Test rig for the determination of material characteristics

With these highly energy-efficient test rigs, you can determine the material characteristics of different rotating transmission elements such as gears, worm gears as well as bevel and ring gears. During the test run, the speed, torque, vibration, oil pressure, oil flow rate and temperature are continuously recorded, monitored and evaluated by the system control unit. The test sequences can be individually programmed using the touch panel.

Technical data and equipment ■ Variable speed: 0 – 15,000 rpm Rotation speed gradient: < 40,000 rpm/sec■ Variable torque: 0 – 1200 Nm■ Shaft angle: 0° (optionally 90°)■ Center distance: 90 – 200 mm■ Temp. (cooling and heating): - 40° C to + 250° C■ Vibration analysis for damage detection■ Oil lubrication ■ Network connection (evaluation using LabView)

Tests■ Endurance testing of gears of different diameters■ Especially suited for high speeds and torques ■ Determined characteristics: Wear particles, efficiency, tooth root bend, speed, torque, temperature, vibration■ Target sectors: Automotive and petroleum industry

Technical data and equipment ■ Speed 60 rpm – 6000 rpm■ Max. torque: 1650 Nm (sprocket)■ Flexibly adjustable center distance: 51 mm – 140 mm■ Oil lubrication ■ Cooling / heating■ Vibration analysis for damage detection

Gear test rig with variable center distance

With this compact special test rig, you can test different gear designs for center distances of 89 mm to 140 mm. With high torques of up to 1650 Nm and a maximum speed of up to 6000 rpm, you can, for example, de-termine the limiting stress capacity of lubricants for high-power engines.

Tests■ Test procedure according to ISO 12152■ Determined characteristics: Volume of the oil-air dispersion, temperature■ Target sectors: Automotive and petroleum industry

Technical data and equipment ■ Standard speed: 1440 rpm■ Optional speed: 0 – 2,000 rpm■ Oil temperature: 25° C ■ (optionally programmable oil temperature from -5 ° C to + 120 ° C)■ Contact heating

System Flender oil foam test ISO 12152

In general, oil manufacturers test the foam characteristics of oils according to the ANSI / ASTM D 892 method or the similar method according to DIN 51566, in which air is blown into an oil sample for a specified time. As the results of this test often do not cor-respond to the foam characteristics determined in gearboxes, a more practical test facility has been developed. With the Flender foam tester, a pair of gears rotates in the tested oil, mixing an oil-air dispersion. The surface foam, the change in volume of the oil-air disper-sion as well as its reduction are tested under the same real conditions as those found in gearboxes.

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Tests■ Evaluation of oils and lubricants ■ Determined characteristics: Temperature, viscosity, speed, torque, vibration and efficiency■ Target sectors: Petroleum industry and gear manufacturers

Technical data and equipment ■ Drive speed: 3,000 rpm■ Drive torque: 100 Nm■ Temperature (cooling and heating): - 20° C to + 120° C■ Vibration monitoring for damage analysis ■ Efficiency measurement■ Oil condition monitoring

Worm gear test rig

The service life and the energy efficiency of worm gears strongly depends on the right choice of suitable gearbox oils. This compact test rig enables oil and lubricant manufacturers to test their products under specific operating conditions.

With the characteristics measured directly at the worm shaft, such as temperature, viscosity, torque, vibration and efficiency, an automatic defect analysis is possible and the lubricant can be evaluated accor-dingly.

Tests■ Fatigue strength testing of planetary gearbox ■ Test two planetary gearboxes simultaneously ■ Determined characteristics: Speed, torque, temperature, vibration, efficiency■ Target sectors: Automotive and petroleum industry

Technical data and equipment ■ Power: 190 kW■ Speed: < 15,000 rpm■ Torque: < 1,200 Nm■ Max. oil flow: 10 l/min■ Max. oil temperature: 140° C

Back-to-back planetary gearbox test rig

This test rig tests the fatigue strength of different planetary gearboxes. Variety is ensured by variable adapter plates onto which the different gearboxes are mounted. One motor generates the speed, a second one the torque.

Tests■ Testing antifriction bearings for wear and slip■ Determined characteristics: Speed, torque, temperature, vibration, efficiency■ Target sectors: Automotive and petroleum industry, manufacturers of antifriction and slide bearings

Technical data and equipment ■ Speed: 0 – 4,000 rpm■ Radial force: 0 – 200 kN■ Axial force: 0 – 200 kN■ Temperature: - 20° C to + 120° C

Antifriction bearing test rig

On this test rig, antifriction bearings can be tested for wear and slip. By means of three mechatronic actuators, a dynamic simulation of the radial force of 360° and the axial force can applied to the test bearing during the test run. The integrated measuring systems of the actuators allow a precise application of the specified forces. Furthermore, the test bearing can be subjected to additional load by tilting and skewing.

Tests■ Testing antifriction and slide bearings or bearing/shaft combinations for wear or fatigue strength■ Simulation of high power frequencies ■ Especially suited for high speeds ■ Determined characteristics: Speed, torque, temperature, vibration, efficiency■ Target sectors: Automotive and petroleum industry, manufacturers of antifriction and slide bearings

Technical data and equipment ■ Variable speed: 0 – 100,000 rpm■ Variable radial force: 0 – 200 kN■ Variable axial force: 0 – 200 kN■ Tilting and skewing of the bearing■ Temperature (cooling and heating): - 40° C to + 150° C■ Vibration monitoring

Antifriction bearing test rig / slide bearing test rig

On this test rig, different types of antifriction and slide bearings or bearing/shaft com-binations can be tested for wear or fatigue strength. A mechatronic actuator allows the dynamic simulation of the radial forces or the deflection of the shaft during the test run and the test temperature can be adjusted between – 40 and + 150 °C.

Speed, torque, vibration, power, distance, oil pressure, oil flow rate and temperature are continuously recorded and evaluated by the system control unit. The test sequences can be individually programmed and the test results can be represented graphically.

Tests■ Testing the bearings of turbochargers■ Especially suited for high speeds of > 150.000 rpm ■ Determined characteristics: Speed, torque, temperature, vibration■ Target sectors: Automotive and petroleum industry

Technical data and equipment ■ Power: 7 kW■ Variable speed: 10,000 – 150,000 rpm■ Axial shaft load: 300 N (static)■ Axial shaft load: ± 200 N (dynamic, max. 300 Hz)

Bearing test rig for turbochargers

This test rig is used to test new or improved bearing concepts for turbochargers, as well as for permanent quality monitoring.

Tests■ Long-term testing of rear axle gears ■ Especially suited for high torques ■ Determined characteristics: Speed, torque, temperature, vibration■ Target sectors: Automotive and petroleum industry

Technical data and equipment ■ Variable speed: 0 – 6,000 rpm■ Torque: 0 – 2,000 Nm■ Vibration monitoring■ Temperature (cooling and heating): - 20° C to + 140° C■ Network connection (evaluation using LabView)

Hypoid gear test rig

The programmable load cycle test rig for rear axle gears is designed especially for long-term tests at high torques. Two hypoid gearboxes (test gearbox and drive gearbox) are connected to a spur gearbox by torsion shafts. To enable dynamic test procedures, the load torque is automatically applied via a hydraulic load clutch.

To be able to compare the bearings and bearing types, the friction power and load capacity are determined mea-suring the shaft torque and friction power using precise high-performance sensors. In addition, a realistic, axial shaft load (static and dynamic) can be applied.

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Due to the back-to-back arrange-ment of the gearboxes, two gear-boxes can be tested simultaneously. With an additional regenerative unit an efficiency of up to 94 % can be reached. The defect analysis is carried out automatically.

Tests■ Endurance testing of propshaft greases or propshafts■ Determined characteristics: Speed, torque, temperature, bending angle and angle of deflection■ Target sectors: Automotive industry

Technical data and equipment ■ Variable speed: 0 – 4,500 rpm■ Variable load torque: 0 – 3,000 Nm■ Variable bending angle: 0 – 20°■ Variable angle of deflection: 0 – 60°■ Cooling and heating up to max. + 150° C

Propshaft test rig for four shafts

This test rig is based on a power circuit and is used to test the endurance of propshaft greases or propshafts. Four propshafts can be tested simultaneously under variable head wind conditions and bellow defects are detected automatically. The hydraulic load clutch, the spindle units to set the bending angle and angle of deflection as well as the circulating air heater boxes are actuated by the test rig control system and are freely pro-grammable over time, in addition to the speed.

Tests■ Endurance testing of propshafts and driveshafts with shock simulation■ Typical test pieces: Cardan shafts, propshafts, PTO shafts and driveshafts ■ Especially suited for high torques ■ Target sectors: Automotive industry

Technical data and equipment ■ Variable speed: 0 – 6,000 rpm ■ Variable load torque: 0 – 150,000 Nm■ Variable shock movement: max. 300 mm■ Variable shock speed: 2-3 m/sec■ Shaft lengths: 300 mm – 2000 mm

Driveshaft test rig

This test rig is based on the power circuit principle and is used to test the endurance of propshafts and driveshafts of different diameters and lengths at variable head wind condi-tions. During the test run, the speed, torque, vibration, shock speed and number of shock movements as well as the temperature are continuously recorded by the system control unit and can be graphically represented on the touch panel.

Tests■ Acoustic noise evaluation of gears or gearboxes■ Determined characteristics: Speed, torque, temperature, vibration, efficiency, acoustics■ Target sectors: Automotive and petroleum industry

Technical data and equipment ■ Speed: 0 – 15,000 rpm■ Torque: up to 600 Nm■ Noise level: <55 dba

Gearbox test rig for acoustic testing

With this special test rig the noise behavior of different types of gears, gearbox elements and entire gearboxes can be tested by means of acoustic testing with level measurements under 55 dB(A). A single-stage test gearbox is used as the basis, designed for spur gearing (straight and helical gears) and with variable axle offset. At the drive side, the rotation is initiated by an electric motor and the torque at the output side (generator) is initiated by a DC link system. This test rig is available with different torque and speed ranges according to customer requirements.

Tests■ Fatigue strength testing of gearboxes ■ Flexible test setup: complete gearboxes or gear pairs ■ Suited for high torques and speeds ■ Determined characteristics: Speed, torque, temperature, vibration■ Target sectors: Automotive and petroleum industry, gear manufacturers

Technical data and equipment ■ Speed: < 15,000 rpm■ Torque: < 4,500 Nm■ Power: < 600 kW

Endurance test rig for gearboxes

The endurance test rig for gearboxes consists of three electric motors and is fully electronic. With a unique positioning system, the electric motors can be easily adapted or positioned on the respective test application. Complete gearboxes in „T“ arrangement or, for example, only gear pairs in „I“ arrangement can be tested for fatigue strength.

TestsDetermined characteristics: ■ Runtime and flow rate■ Flow and differential pressure filter■ Inlet and outlet humidity ■ Inlet and outlet temperature■ Tank pressure and oil temperature

Technical data and equipment ■ Dimensions: 1.0 m x 0.8 m x 1.2 m■ Flow rate: 0.2 – 1 l/min■ Temperature: max. 90° C■ Pressure: max. 10 bar■ Dosing pump■ Humidity measurement

Filterability test rig

The filterability test rig is used to test the filtration properties of liquid lubricants. During the test run, the testing medium is heated, a controlled amount of water is added and the medium is pumped through the filter. Characteristic data such as flow rate, differential pressure, temperature and humidity are recorded and evaluated by the control system. Moreover, the Flender oil foam test system (please refer to page 10) can be used to de-termine the foaming characteristics of the testing medium in accordance with ISO 12152

prior to and after the filterability test. The filterability test rig is manufactured under the license of the company ISP

Salzbergen GmbH & Co. KG.

Tests■ Testing the characteristics and service life of propshafts■ Determined characteristics: Speed, torque, temperature, vibration, displacement force■ Target sectors: Automotive industry

Technical data and equipment ■ Variable speed: 0 – 4,000 rpm■ Variable torque: 0 – 200 Nm■ Variable bending torque: 0 – 200 Nm■ Variable bending angle: 60°■ Shaft length: 200 mm – 120 mm■ Circumferential backlash on fixed and/or sliding joint ■ Axial backlash with displacement force on fixed and/or sliding joint ■ Bending torque at a specific speed and angle of deflection ■ Starting torque

Propshaft test rig

This multi-flexible test rig subjects the propshafts to different angles of deflection, ben-ding angles, torques and speeds, simulating different strains, as for example those that arise when driving through cities or on the highway, head wind, overheating or driving on winding roads and in mountainous regions. Different types of propshafts can be adapted. During the test run, the speed, torque, axial force, circumferential and axial backlash are continuously recorded, evaluated using the system control unit and can be graphically represented on the touch panel.

Generator 1Generator 2

Motor

T-Nuten Platte

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Tests■ Simulation of the drying process in washing facilities■ Determined characteristics: Deformation, vibration■ Target sectors: Automotive industry Technical data and equipment ■ Performance: 2 x 11 kW■ Travel distance: X 2500 mm Y 1000 mm each Z 700 mm each■ Precise laser measurement■ Video recording during the test run

Blower test rig

With the blower test rig the drying process in washing facilities can be simulated. An appropriate air flow is applied to the vehicle by means of the blowers and the occurring vibrations/deformations are measured with precise laser sensors. The test sequence is recorded on video. The blowers can be positioned automatically on the X axis and inde-pendently of each other on the Y and Z axes.

Tests■ Determination of performance/efficiency measurement of turbines or compressor wheels■ Especially suited for high speeds of more than 150.000 rpm.■ Determined characteristics: Speed, torque, temperature, vibration■ Target sectors: Automotive industry

Technical data and equipment ■ Power: 7 kW■ Speed: 10,000 – 120,000 rpm■ High-speed torque measurement: < 1.2 Nm (dynamic)■ High-speed rpm sensor■ Vibration monitoring

Turbine wheel test rig

This special test rig is used to determine the performance and efficiency of turbines or compressor wheels. It is especially suited for high speeds of more than 150.000 rpm.

A high-speed torquemeter that measures torques of even less than 1.2 Nm is mounted onto the driveshaft. The test rig is used to optimize new developments and to ensure the quality of standard products.

Area of application■ Endurance testing of bevel gears of different diameters■ Determined characteristics: Speed, torque, temperature, vibration, efficiency■ Target sectors: Aviation, automotive and petroleum industry

Technical data and equipment ■ Performance: 2 x 156 kW ■ Variable speed: 0 – 12,000 rpm ■ Variable torque 1: 400 Nm at up to 4,500 rpm ■ Variable torque 2: 100 Nm at 12,000 rpm■ Variable adjustment of the shaft angle and center distances ■ Scuffing and pitting detection ■ Efficiency measurement ■ Oil lubrication and oil temperature control

Bevel gear test rig TS-30

Bevel gears sets of different sizes can be tested for wear and fatigue strength on the bevel gear test rigs. Electric drives initiate the rotary motion at the drive side (motor) and the brake torque at the output side (generator). This elaborate concept provides for highly energy-efficient tests.

The center distances and shaft angles between the bevel gears can be individually adjusted using the control unit. During the test run, the speed, torque, vibrations, oil pressure, oil flow rate and temperature are continuously recorded and evaluated via the system control unit. All test sequences can be individually programmed using the touch panel. To measure the torque and tooth root bend, the workpiece carriers are equipped with a telemetry system (DMS application) located directly at the test piece. The position and the high precision of the DMS measuring system also makes it possible to measure the efficiency. The TS 30 bevel gear test rig was developed in close collaboration with the mechanical engineering company KLINGELNBERG, one of the leading manufacturers in the gearing industry. The perfect coordination of development and engineering processes resulted in a high-precision end product that meets even the highest customer expectations.

For more detailed information on our exclusive partnership contract (bevel gear test rig), please visit www.klingelnberg.com.

Tests■ Service life and wear testing of different clutches■ Typical test pieces: Bellow, claw, shaft coupling, etc. ■ Target sectors: Automotive industry clutch manufacturers

Technical data and equipment ■ Variable speed: 0 – 10,000 rpm■ Mechatronic torque: 700 Nm■ Hydraulic torque: 150,000 Nm

Clutch test rig

This clutch test rig, based on the power circuit principle, is used to test the service life and wear of different clutches like bellow, claw and shaft couplings etc. Shaft misalignment simulation is done automatically.

During the test run, dynamic axial and radial loading of the test clutch is possible with a swash plate. Axial and radial force, vibration, torque, torsion angle and temperature are continuously recorded and can be graphically represented on the touch panel.

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